Surgical staple cartridges with driver arrangements for establishing herringbone staple patterns

ABSTRACT

A surgical staple driver array for operable use in a surgical staple cartridge. A plurality of first staple drivers is configured to be slidably supported in the surgical staple cartridge. Each first staple driver is configured to operably support at least two first surgical staples thereon that are parallel to each other. A plurality of second staple drivers is configured to be slidably supported in the surgical staple cartridge adjacent to at least one corresponding first staple driver. Each second staple driver supports a single, second surgical staple thereon. The second surgical staple extends in a second direction that is transverse to each of the first surgical staples supported on the at least one adjacent corresponding first staple driver.

BACKGROUND

The present invention relates to surgical instruments and, in various embodiments, to surgical stapling and cutting instruments and staple cartridges for use therewith.

A stapling instrument can include a pair of cooperating elongate jaw members, wherein each jaw member can be adapted to be inserted into a patient and positioned relative to tissue that is to be stapled and/or incised. In various embodiments, one of the jaw members can support a staple cartridge with at least two laterally spaced rows of staples contained therein, and the other jaw member can support an anvil with staple-forming pockets aligned with the rows of staples in the staple cartridge. Generally, the stapling instrument can further include a pusher bar and a knife blade which are slidable relative to the jaw members to sequentially eject the staples from the staple cartridge via camming surfaces on the pusher bar and/or camming surfaces on a wedge sled that is pushed by the pusher bar. In at least one embodiment, the camming surfaces can be configured to activate a plurality of staple drivers carried by the cartridge and associated with the staples in order to push the staples against the anvil and form laterally spaced rows of deformed staples in the tissue gripped between the jaw members. In at least one embodiment, the knife blade can trail the camming surfaces and cut the tissue along a line between the staple rows.

The foregoing discussion is intended only to illustrate various aspects of the related art in the field of the invention at the time, and should not be taken as a disavowal of claim scope.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of a surgical instrument and an elongate shaft assembly embodiment;

FIG. 2 is an exploded assembly view of the handle or housing portion of the surgical instrument of FIG. 1;

FIG. 3 is an exploded assembly view of a portion of an elongate shaft assembly;

FIG. 4 is another exploded assembly view of another portion of the elongate shaft assembly of FIG. 3;

FIG. 5 is a perspective view of a portion of a surgical end effector embodiment;

FIG. 6 is an exploded assembly view of the surgical end effector of FIG. 5;

FIG. 7 is a top view of a surgical staple cartridge embodiment;

FIG. 8 is a bottom view of the surgical staple cartridge embodiment of FIG. 7;

FIG. 9 depicts the staple pattern deployed by the cartridge of FIGS. 7 and 8;

FIG. 10 depicts the staple pattern of FIG. 9 in a stretched condition;

FIG. 11 depicts a previous staple pattern implanted in tissue;

FIG. 12 is a perspective view of a staple driver embodiment;

FIG. 13 is a top view of the staple driver embodiment of FIG. 12;

FIG. 14 is a bottom perspective view of the staple driver of FIGS. 12 and 13;

FIG. 15 is a bottom perspective view of a portion of a surgical staple cartridge embodiment;

FIG. 16 is a top view of corresponding driver arrays employed in the surgical staple cartridge of FIG. 15;

FIG. 17 is another top view of one of the driver arrays of FIG. 16 supported in corresponding portions of a staple cartridge embodiment;

FIG. 18 is a top view of portions of the driver arrays of FIGS. 16 and 17 in connection with a sled or camming actuator of a surgical instrument;

FIG. 19 is a front elevational view of the driver array and sled/cam actuator depicted in FIG. 18;

FIG. 20 is a top view of corresponding portions of other driver array embodiments;

FIG. 21 is another top view of one of the driver arrays of FIG. 20;

FIG. 22 is a top view of a distal driver of the driver array illustrated in FIG. 20;

FIG. 23 is a perspective view of the distal driver of FIG. 22 supporting a staple thereon;

FIG. 24 is a bottom perspective view of the distal driver of FIGS. 22 and 23;

FIG. 25 is a top view of a proximal driver of the driver array depicted in FIG. 20;

FIG. 26 is a perspective view of the proximal driver of FIG. 25 supporting a staple thereon;

FIG. 27 is a bottom perspective view of the proximal driver of FIGS. 25 and 26;

FIG. 28 is a top view of corresponding portions of other driver array embodiments;

FIG. 29 is a top view of one of the driver arrays of FIG. 28;

FIG. 30 is a top view of one of the drivers of the driver array of FIG. 29;

FIG. 31 is a perspective view of the driver of FIG. 30 supporting four staples thereon;

FIG. 32 is a bottom perspective view of the driver of FIGS. 30 and 31;

FIG. 33 is a top view of corresponding portions of other driver array embodiments;

FIG. 34 is a top view of one of the driver arrays of FIG. 33;

FIG. 35 is a top view of a proximal driver of the driver array of FIG. 34;

FIG. 36 is a perspective view of the driver of FIG. 35 supporting three staples thereon;

FIG. 37 is a bottom perspective view of driver of FIGS. 35 and 36;

FIG. 38 is a top view of a distal driver of the driver array of FIG. 34;

FIG. 39 is a perspective view of the driver of FIG. 38 supporting two staples thereon;

FIG. 40 is a bottom perspective view of the driver of FIGS. 38 and 39;

FIG. 41 is a top view of corresponding portions of other driver array embodiments;

FIG. 42 is a top view of one of the driver arrays of FIG. 41;

FIG. 43 is a top view of a distal driver of the driver array of FIG. 42;

FIG. 44 is a perspective view of the driver of FIG. 43 supporting three staples thereon;

FIG. 45 is a bottom perspective view of the driver of FIGS. 43 and 44;

FIG. 46 is a top view of a proximal staple driver of the driver array of FIG. 42;

FIG. 47 is a perspective view the driver of FIG. 46 supporting two staples thereon;

FIG. 48 is a bottom perspective view of the driver of FIGS. 46 and 47;

FIG. 49 is a top view of corresponding portions of other driver array embodiments;

FIG. 50 is a top view of one of the driver arrays of FIG. 49;

FIG. 50A is an enlarged view of a portion of the driver array of FIG. 50;

FIG. 50B is an enlarged view of another portion of the driver array of FIG. 50;

FIG. 51 is a top view of one of the drivers of the driver array depicted in FIG. 50;

FIG. 52 is a perspective view of the driver of FIG. 51 supporting a total of five staples thereon;

FIG. 53 is a bottom perspective view of the driver of FIGS. 51 and 52;

FIG. 54 is a top view of another driver of the driver array of FIG. 50;

FIG. 55 is a perspective view of the driver of FIG. 54 supporting four staples thereon;

FIG. 56 is a bottom perspective view of the driver of FIG. 55;

FIG. 57 is a top view of corresponding portions of other driver array embodiments;

FIG. 58 is a top view of one of the driver arrays of FIG. 57;

FIG. 59 is a top view of a distal driver of the driver array depicted in FIG. 58;

FIG. 60 is a perspective view of the distal driver of FIG. 59 supporting two staples thereon;

FIG. 61 is a bottom perspective view of the driver of FIGS. 59 and 60;

FIG. 62 is a top view of corresponding portions of other driver array embodiments;

FIG. 63 is a top view of one of the driver arrays of FIG. 62 in connection with a portion of a surgical staple cartridge;

FIG. 64 is a top view of one of the drivers of the driver arrays of FIGS. 62 and 63;

FIG. 65 is a perspective view of the driver of FIG. 64 supporting a staple thereon;

FIG. 66 is a bottom perspective view of the driver of FIGS. 64 and 65;

FIG. 67 is a top view of corresponding portions of other driver array embodiments;

FIG. 68 is an enlarged top view of one of the driver arrays of FIG. 67;

FIG. 69 is a top view of first, second and third staple driver embodiments of the staple driver arrays of FIGS. 67 and 68;

FIG. 70 is a perspective view of one of the staple drivers of FIG. 69;

FIG. 71 is a bottom perspective view of the driver of FIG. 70;

FIG. 72 is a perspective view of a surgical staple cartridge that employs the staple driver arrays of FIGS. 67 and 68;

FIG. 73 is a partial bottom perspective view of the surgical staple cartridge of FIG. 72;

FIG. 74 is a perspective view of a portion of another surgical staple cartridge embodiment; and

FIG. 75 is a view of three formed surgical staples that were formed using the surgical staple cartridge of FIG. 74.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following patent applications that were filed on Sep. 2, 2015 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/843,168, entitled SURGICAL         STAPLE CARTRIDGE WITH IMPROVED STAPLE DRIVER CONFIGURATIONS, now         U.S. Patent Application Publication No. 2017/0056011;     -   U.S. patent application Ser. No. 14/843,196, entitled SURGICAL         STAPLE DRIVER ARRAYS, now U.S. Patent Application Publication         No. 2017/0056012;     -   U.S. patent application Ser. No. 14/843,216, entitled SURGICAL         STAPLE CARTRIDGE STAPLE DRIVERS WITH CENTRAL SUPPORT FEATURES,         now U.S. Patent Application Publication No. 2017/0056013; and     -   U.S. patent application Ser. No. 14/843,243, entitled SURGICAL         STAPLE CONFIGURATIONS WITH CAMMING SURFACES LOCATED BETWEEN         PORTIONS SUPPORTING SURGICAL STAPLES, now U.S. Patent         Application Publication No. 2017/0056014.

Applicant of the present application owns the following patent applications that were filed on Mar. 6, 2015 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/640,746, entitled POWERED         SURGICAL INSTRUMENT;     -   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE         LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL         INSTRUMENTS;     -   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE         TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR         MULTIPLE TISSUE TYPES;     -   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID         MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE         TISSUE COMPRESSION;     -   U.S. patent application Ser. No. 14/640,831, entitled MONITORING         SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED         SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/640,859, entitled TIME         DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY,         CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES;     -   U.S. patent application Ser. No. 14/640,817, entitled         INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/640,844, entitled CONTROL         TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH         SELECT CONTROL PROCESSING FROM HANDLE;     -   U.S. patent application Ser. No. 14/640,837, entitled SMART         SENSORS WITH LOCAL SIGNAL PROCESSING;     -   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR         DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A         SURGICAL STAPLER;     -   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND         POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT; and     -   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL         INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING.

Applicant of the present application owns the following patent applications that were filed on Feb. 27, 2015, and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL         INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION;     -   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL         APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER         OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE         BAND;     -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL         CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE         BATTERIES;     -   U.S. patent application Ser. No. 14/633,566, entitled CHARGING         SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A         BATTERY;     -   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR         MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED;     -   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED         BATTERY FOR A SURGICAL INSTRUMENT;     -   U.S. patent application Ser. No. 14/633,548, entitled POWER         ADAPTER FOR A SURGICAL INSTRUMENT;     -   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE         SURGICAL INSTRUMENT HANDLE;     -   U.S. patent application Ser. No. 14/633,541, entitled MODULAR         STAPLING ASSEMBLY; and     -   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL         APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER.

Applicant of the present application owns the following patent applications that were filed on Dec. 18, 2014 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL         INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND         MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING;     -   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL         INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS;     -   U.S. patent application Ser. No. 14/575,139, entitled DRIVE         ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/575,148, entitled LOCKING         ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE         SURGICAL END EFFECTORS;     -   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL         INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A         DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE;     -   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL         INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS;     -   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL         INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING         BEAM SUPPORT ARRANGEMENTS;     -   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL         INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING         BEAM SUPPORT ARRANGEMENTS;     -   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL         INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM;         and     -   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL         INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM.

Applicant of the present application owns the following patent applications that were filed on Mar. 1, 2013 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/782,295, entitled         ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR         SIGNAL COMMUNICATION, now U.S. Patent Application Publication         No. 2014/0246471;     -   U.S. patent application Ser. No. 13/782,323, entitled ROTARY         POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S.         Patent Application Publication No. 2014/0246472;     -   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL         SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent         Application Publication No. 2014/0249557;     -   U.S. patent application Ser. No. 13/782,499, entitled         ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT,         now U.S. Patent Application Publication No. 2014/0246474;     -   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE         PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now         U.S. Patent Application Publication No. 2014/0246478;     -   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK         SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Patent         Application Publication No. 2014/0246477;     -   U.S. patent application Ser. No. 13/782,481, entitled SENSOR         STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now         U.S. Patent Application Publication No. 2014/0246479;     -   U.S. patent application Ser. No. 13/782,518, entitled CONTROL         METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT         PORTIONS, now U.S. Patent Application Publication No.         2014/0246475;     -   U.S. patent application Ser. No. 13/782,375, entitled ROTARY         POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM,         now U.S. Patent Application Publication No. 2014/0246473; and     -   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL         INSTRUMENT SOFT STOP, now U.S. Patent Application Publication         No. 2014/0246476.

Applicant of the present application also owns the following patent applications that were filed on Mar. 14, 2013 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/803,097, entitled         ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now         U.S. Patent Application Publication No. 2014/0263542;     -   U.S. patent application Ser. No. 13/803,193, entitled CONTROL         ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now         U.S. Patent Application Publication No. 2014/0263537;     -   U.S. patent application Ser. No. 13/803,053, entitled         INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL         INSTRUMENT, now U.S. Patent Application Publication No.         2014/0263564;     -   U.S. patent application Ser. No. 13/803,086, entitled         ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION         LOCK, now U.S. Patent Application Publication No. 2014/0263541;     -   U.S. patent application Ser. No. 13/803,210, entitled SENSOR         ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL         INSTRUMENTS, now U.S. Patent Application Publication No.         2014/0263538;     -   U.S. patent application Ser. No. 13/803,148, entitled         MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent         Application Publication No. 2014/0263554;     -   U.S. patent application Ser. No. 13/803,066, entitled DRIVE         SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,         now U.S. Patent Application Publication No. 2014/0263565;     -   U.S. patent application Ser. No. 13/803,117, entitled         ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL         INSTRUMENTS, now U.S. Patent Application Publication No.         2014/0263553;     -   U.S. patent application Ser. No. 13/803,130, entitled DRIVE         TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now         U.S. Patent Application Publication No. 2014/0263543; and     -   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND         SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent         Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patent application that was filed on Mar. 7, 2014 and is herein incorporated by reference in its entirety:

-   -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL         SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application         Publication No. 2014/0263539.

Applicant of the present application also owns the following patent applications that were filed on Mar. 26, 2014 and are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/226,106, entitled POWER         MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/226,099, entitled         STERILIZATION VERIFICATION CIRCUIT;     -   U.S. patent application Ser. No. 14/226,094, entitled         VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT;     -   U.S. patent application Ser. No. 14/226,117, entitled POWER         MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE         UP CONTROL;     -   U.S. patent application Ser. No. 14/226,075, entitled MODULAR         POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES;     -   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK         ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL         INSTRUMENT UTILIZING SENSOR ADAPTATION;     -   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL         INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR;     -   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL         INSTRUMENT COMPRISING INTERACTIVE SYSTEMS;     -   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE         SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS;     -   U.S. patent application Ser. No. 14/226,133, entitled MODULAR         SURGICAL INSTRUMENT SYSTEM;     -   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS         AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT;     -   U.S. patent application Ser. No. 14/226,076, entitled POWER         MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE         PROTECTION;     -   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL         STAPLING INSTRUMENT SYSTEM; and     -   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL         INSTRUMENT COMPRISING A ROTATABLE SHAFT.

Applicant of the present application also owns the following patent applications that were filed on Sep. 5, 2014 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY         AND SENSORS FOR POWERED MEDICAL DEVICE;     -   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT         WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION;     -   U.S. patent application Ser. No. 14/478,908, entitled MONITORING         DEVICE DEGRADATION BASED ON COMPONENT EVALUATION;     -   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE         SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR         INTERPRETATION;     -   U.S. patent application Ser. No. 14/479,110, entitled USE OF         POLARITY OF HALL MAGNET DETECTION TO DETECT MISLOADED CARTRIDGE;     -   U.S. patent application Ser. No. 14/479,098, entitled SMART         CARTRIDGE WAKE UP OPERATION AND DATA RETENTION;     -   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE         MOTOR CONTROL FOR POWERED MEDICAL DEVICE; and     -   U.S. patent application Ser. No. 14/479,108, entitled LOCAL         DISPLAY OF TISSUE PARAMETER STABILIZATION.

Applicant of the present application also owns the following patent applications that were filed on Apr. 9, 2014 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR         DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now         U.S. Patent Application Publication No. 2014/0305987;     -   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL         INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE         OPERATED FROM THE SAME ROTATABLE OUTPUT, now U.S. Patent         Application Publication No. 2014/0305989;     -   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL         INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE         OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent         Application Publication No. 2014/0305988;     -   U.S. patent application Ser. No. 14/248,588, entitled POWERED         LINEAR SURGICAL STAPLER, now U.S. Patent Application Publication         No. 2014/0309666;     -   U.S. patent application Ser. No. 14/248,591, entitled         TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S.         Patent Application Publication No. 2014/0305991;     -   U.S. patent application Ser. No. 14/248,584, entitled MODULAR         MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR         ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS,         now U.S. Patent Application Publication No. 2014/0305994;     -   U.S. patent application Ser. No. 14/248,587, entitled POWERED         SURGICAL STAPLER, now U.S. Patent Application Publication No.         2014/0309665;     -   U.S. patent application Ser. No. 14/248,586, entitled DRIVE         SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now         U.S. Patent Application Publication No. 2014/0305990; and     -   U.S. patent application Ser. No. 14/248,607, entitled MODULAR         MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION         ARRANGEMENTS, now U.S. Patent Application Publication No.         2014/0305992.

Applicant of the present application also owns the following patent applications that were filed on Apr. 16, 2013 and which are each herein incorporated by reference in their respective entireties:

-   -   U.S. Provisional Patent Application Ser. No. 61/812,365,         entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED         BY A SINGLE MOTOR;     -   U.S. Provisional Patent Application Ser. No. 61/812,376,         entitled LINEAR CUTTER WITH POWER;     -   U.S. Provisional Patent Application Ser. No. 61/812,382,         entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;     -   U.S. Provisional Patent Application Ser. No. 61/812,385,         entitled SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION         MOTORS AND MOTOR CONTROL; and     -   U.S. Provisional Patent Application Ser. No. 61/812,372,         entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED         BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical instrument. The term “proximal” refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the instruments can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected ahead of the knife.

A surgical fastening instrument 10 is depicted in FIG. 1. The surgical fastening instrument 100 is configured to deploy an “elastic” or “expandable” staple line. Various elastic staple lines are disclosed herein and the surgical fastening instrument 10 is capable of deploying any one of these elastic staple lines. Moreover, surgical instruments other than the surgical fastening instrument 100 are capable of deploying any one of the expandable staple lines disclosed herein.

As can be seen in FIGS. 1-4, the surgical fastening instrument 10 includes a housing 12 that comprises a handle 14 that is configured to be grasped, manipulated and actuated by the clinician. The housing 12 is configured for operable attachment to an elongate shaft assembly 200 that has a surgical end effector 700 operably coupled thereto that is configured to perform one or more surgical tasks or procedures. The elongate shaft assembly 200 may be interchangeable with other shaft assemblies in the various manners disclosed, for example, in U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, the entire disclosure of which is hereby incorporated by reference herein. In other arrangements, the elongate shaft assembly may not be interchangeable with other shaft assemblies and essentially comprise a dedicated non-removable portion of the instrument. It will be further understood that the various forms of shaft assemblies and end effectors disclosed herein may also be effectively employed in connection with robotically-controlled surgical systems. Thus, the term “housing” may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system that is configured to generate and apply at least one control motion which could be used to actuate the elongate shaft assemblies disclosed herein and their respective equivalents. The term “frame” may refer to a portion of a handheld surgical instrument. The term “frame” may also represent a portion of a robotically controlled surgical instrument and/or a portion of the robotic system that may be used to operably control a surgical instrument. For example, the shaft assemblies and end effector arrangements disclosed herein may be employed with various robotic systems, instruments, components and methods disclosed in U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, which is hereby incorporated by reference herein in its entirety.

FIG. 1 illustrates the housing 12 or handle 14 of the surgical instrument 10 with an interchangeable elongate shaft assembly 200 operably coupled thereto. As can be seen in FIG. 1, the handle 14 may comprise a pair of interconnectable handle housing segments 16 and 18 that may be interconnected by screws, snap features, adhesive, etc. In the illustrated arrangement, the handle housing segments 16, 18 cooperate to form a pistol grip portion 19 that can be gripped and manipulated by the clinician. As will be discussed in further detail below, the handle 14 operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of the interchangeable shaft assembly that is operably attached thereto.

Referring now to FIG. 2, the handle 14 may further include a frame 20 that operably supports a plurality of drive systems. For example, the frame 20 can operably support a “first” or closure drive system, generally designated as 30, which may be employed to apply closing and opening motions to the elongate shaft assembly 200 that is operably attached or coupled thereto. In at least one form, the closure drive system 30 may include an actuator in the form of a closure trigger 32 that is pivotally supported by the frame 20. More specifically, as illustrated in FIG. 2, the closure trigger 32 is pivotally coupled to the housing 14 by a pin 33. Such arrangement enables the closure trigger 32 to be manipulated by a clinician such that when the clinician grips the pistol grip portion 19 of the handle 14, the closure trigger 32 may be easily pivoted from a starting or “unactuated” position to an “actuated” position and more particularly to a fully compressed or fully actuated position. The closure trigger 32 may be biased into the unactuated position by spring or other biasing arrangement (not shown). In various forms, the closure drive system 30 further includes a closure linkage assembly 34 that is pivotally coupled to the closure trigger 32. As can be seen in FIG. 2, the closure linkage assembly 34 may include a first closure link 36 and a second closure link 38 that are pivotally coupled to the closure trigger 32 by a pin 35. The second closure link 38 may also be referred to herein as an “attachment member” and include a transverse attachment pin 37.

Still referring to FIG. 2, it can be observed that the first closure link 36 may have a locking wall or end 39 thereon that is configured to cooperate with a closure release assembly 60 that is pivotally coupled to the frame 20. In at least one form, the closure release assembly 60 may comprise a release button assembly 62 that has a distally protruding locking pawl 64 formed thereon. The release button assembly 62 may be pivoted in a counterclockwise direction by a release spring (not shown). As the clinician depresses the closure trigger 32 from its unactuated position towards the pistol grip portion 19 of the handle 14, the first closure link 36 pivots upward to a point wherein the locking pawl 64 drops into retaining engagement with the locking wall 39 on the first closure link 36 thereby preventing the closure trigger 32 from returning to the unactuated position. Thus, the closure release assembly 60 serves to lock the closure trigger 32 in the fully actuated position. When the clinician desires to unlock the closure trigger 32 to permit it to be biased to the unactuated position, the clinician simply pivots the closure release button assembly 62 such that the locking pawl 64 is moved out of engagement with the locking wall 39 on the first closure link 36. When the locking pawl 64 has been moved out of engagement with the first closure link 36, the closure trigger 32 may pivot back to the unactuated position. Other closure trigger locking and release arrangements may also be employed.

When the closure trigger 32 is moved from its unactuated position to its actuated position, the closure release button 62 is pivoted between a first position and a second position. The rotation of the closure release button 62 can be referred to as being an upward rotation; however, at least a portion of the closure release button 62 is being rotated toward the circuit board 100. Still referring to FIG. 2, the closure release button 62 can include an arm 61 extending therefrom and a magnetic element 63, such as a permanent magnet, for example, mounted to the arm 61. When the closure release button 62 is rotated from its first position to its second position, the magnetic element 63 can move toward the circuit board 100. The circuit board 100 can include at least one sensor that is configured to detect the movement of the magnetic element 63. In at least one embodiment, a “Hall effect” sensor can be mounted to the bottom surface of the circuit board 100. The Hall effect sensor can be configured to detect changes in a magnetic field surrounding the Hall effect sensor that are caused by the movement of the magnetic element 63. The Hall effect sensor can be in signal communication with a microcontroller, for example, which can determine whether the closure release button 62 is in its first position, which is associated with the unactuated position of the closure trigger 32 and the open configuration of the end effector, its second position, which is associated with the actuated position of the closure trigger 32 and the closed configuration of the end effector, and/or any position between the first position and the second position.

Also in the illustrated arrangement, the handle 14 and the frame 20 operably support another drive system referred to herein as a firing drive system 80 that is configured to apply firing motions to corresponding portions of the interchangeable shaft assembly attached thereto. The firing drive system may 80 also be referred to herein as a “second drive system”. The firing drive system 80 may employ an electric motor 82, located in the pistol grip portion 19 of the handle 14. In various forms, the motor 82 may be a DC brushed driving motor having a maximum rotation of, approximately, 25,000 RPM, for example. In other arrangements, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor 82 may be powered by a power source 90 that in one form may comprise a removable power pack 92. As can be seen in FIG. 2, for example, the power pack 92 may comprise a proximal housing portion 94 that is configured for attachment to a distal housing portion 96. The proximal housing portion 94 and the distal housing portion 96 are configured to operably support a plurality of batteries 98 therein. Batteries 98 may each comprise, for example, a Lithium Ion (“LI”) or other suitable battery. The distal housing portion 96 is configured for removable operable attachment to a control circuit board assembly 100 which is also operably coupled to the motor 82. A number of batteries 98 may be connected in series may be used as the power source for the surgical instrument 10. In addition, the power source 90 may be replaceable and/or rechargeable.

As outlined above with respect to other various forms, the electric motor 82 includes a rotatable shaft (not shown) that operably interfaces with a gear reducer assembly 84 that is mounted in meshing engagement with a with a set, or rack, of drive teeth 122 on a longitudinally-movable drive member 120. In use, a voltage polarity provided by the power source 90 can operate the electric motor 82 in a clockwise direction wherein the voltage polarity applied to the electric motor by the battery can be reversed in order to operate the electric motor 82 in a counter-clockwise direction. When the electric motor 82 is rotated in one direction, the drive member 120 will be axially driven in the distal direction “DD”. When the motor 82 is driven in the opposite rotary direction, the drive member 120 will be axially driven in a proximal direction “PD”. The handle 14 can include a switch which can be configured to reverse the polarity applied to the electric motor 82 by the power source 90. As with the other forms described herein, the handle 14 can also include a sensor that is configured to detect the position of the drive member 120 and/or the direction in which the drive member 120 is being moved.

Actuation of the motor 82 is controlled by a firing trigger 130 that is pivotally supported on the handle 14. The firing trigger 130 may be pivoted between an unactuated position and an actuated position. The firing trigger 130 may be biased into the unactuated position by a spring 132 or other biasing arrangement such that when the clinician releases the firing trigger 130, it may be pivoted or otherwise returned to the unactuated position by the spring 132 or biasing arrangement. In at least one form, the firing trigger 130 can be positioned “outboard” of the closure trigger 32 as was discussed above. In at least one form, a firing trigger safety button 134 may be pivotally mounted to the closure trigger 32 by pin 35. The safety button 134 may be positioned between the firing trigger 130 and the closure trigger 32 and have a pivot arm 136 protruding therefrom. See FIG. 2. When the closure trigger 32 is in the unactuated position, the safety button 134 is contained in the handle 14 where the clinician cannot readily access it and move it between a safety position preventing actuation of the firing trigger 130 and a firing position wherein the firing trigger 130 may be fired. As the clinician depresses the closure trigger 32, the safety button 134 and the firing trigger 130 pivot down wherein they can then be manipulated by the clinician.

As discussed above, the handle 14 includes a closure trigger 32 and a firing trigger 130. The firing trigger 130 can be pivotably mounted to the closure trigger 32. When the closure trigger 32 is moved from its unactuated position to its actuated position, the firing trigger 130 can descend downwardly, as outlined above. After the safety button 134 has been moved to its firing position, the firing trigger 130 can be depressed to operate the motor of the surgical instrument firing system. In various instances, the handle 14 can include a tracking system configured to determine the position of the closure trigger 32 and/or the position of the firing trigger 130.

As indicated above, in at least one form, the longitudinally movable drive member 120 has a rack of drive teeth 122 formed thereon for meshing engagement with a corresponding drive gear 86 of the gear reducer assembly 84. At least one form also includes a manually-actuatable “bailout” assembly 140 that is configured to enable the clinician to manually retract the longitudinally movable drive member 120 should the motor 82 become disabled. The bailout assembly 140 may include a lever or bailout handle assembly 142 that is configured to be manually pivoted into ratcheting engagement with teeth 124 also provided in the drive member 120. Thus, the clinician can manually retract the drive member 120 by using the bailout handle assembly 142 to ratchet the drive member 120 in the proximal direction “PD”. U.S. Pat. No. 8,608,045, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM, discloses bailout arrangements and other components, arrangements and systems that may also be employed with the various instruments disclosed herein, is hereby incorporated by reference in its entirety.

Turning now to FIGS. 1 and 3, the elongate shaft assembly 200 includes a surgical end effector 700 that comprises an elongate channel 702 that is configured to operably support a staple cartridge 800 therein. The end effector 700 may further include an anvil 710 that is pivotally supported relative to the elongate channel 702. As will be discussed in further detail below, the surgical end effector 700 may be articulated relative to the elongate shaft assembly about an articulation joint 270. Various embodiments are also envisioned wherein the end effector is not articulatable. As can be seen in FIGS. 3 and 4, the shaft assembly 200 can further include a proximal housing or nozzle 201 comprised of nozzle portions 202 and 203. The shaft assembly 200 further includes a closure tube 260 which can be utilized to close and/or open an anvil 310 of the end effector 700. As can be seen in FIG. 4, the shaft assembly 200 includes a spine 210 which can be configured to fixably support a shaft frame portion 212 of and articulation lock 350. Details regarding the construction and operation of the articulation lock 350 are set forth in U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent Application Publication No. 2014/0263541, the disclosure of which is hereby incorporated by reference herein in its entirety. The spine 210 is configured to, one, slidably support a firing member 220 therein and, two, slidably support the closure tube 260 which extends around the spine 210. The spine 210 also slidably supports a proximal articulation driver 230. The proximal articulation driver 230 has a distal end 301 that is configured to operably engage the articulation lock 350. In one arrangement, the articulation lock 350 interfaces with an articulation frame 352 that is adapted to operably engage a drive pin (not shown) on the end effector frame (not shown).

In the illustrated arrangement, the spine 210 comprises a proximal end 211 which is rotatably supported in a chassis 240. In one arrangement, for example, the proximal end 211 of the spine 210 has a thread 214 formed thereon for threaded attachment to a spine bearing 216 configured to be supported within the chassis 240. See FIG. 3. Such arrangement facilitates rotatable attachment of the spine 210 to the chassis 240 such that the spine 210 may be selectively rotated about a shaft axis SA-SA relative to the chassis 240. The shaft assembly 200 also includes a closure shuttle 250 that is slidably supported within the chassis 240 such that it may be axially moved relative thereto. As can be seen in FIG. 3, the closure shuttle 250 includes a pair of proximally-protruding hooks 252 that are configured for attachment to the attachment pin 37 that is attached to the second closure link 38 as will be discussed in further detail below. See FIG. 2. A proximal end 261 of the closure tube 260 is coupled to the closure shuttle 250 for relative rotation thereto. For example, a U-shaped connector 263 is inserted into an annular slot 262 in the proximal end 261 of the closure tube 260 and is retained within vertical slots 253 in the closure shuttle 250. See FIG. 3. Such arrangement serves to attach the closure tube 260 to the closure shuttle 250 for axial travel therewith while enabling the closure tube 260 to rotate relative to the closure shuttle 250 about the shaft axis SA-SA. A closure spring 268 is journaled on the closure tube 260 and serves to bias the closure tube 260 in the proximal direction “PD” which can serve to pivot the closure trigger into the unactuated position when the shaft assembly 200 is operably coupled to the handle 14.

As was also indicated above, the elongate shaft assembly 200 further includes a firing member 220 that is supported for axial travel within the shaft spine 210. The firing member 220 includes an intermediate firing shaft portion 222 that is configured for attachment to a distal cutting portion or firing beam 280. The firing member 220 may also be referred to herein as a “second shaft” and/or a “second shaft assembly”. As can be seen in FIG. 4, the intermediate firing shaft portion 222 may include a longitudinal slot 223 in the distal end thereof which can be configured to receive a tab 284 on the proximal end 282 of the distal firing beam 280. The longitudinal slot 223 and the proximal end 282 can be sized and configured to permit relative movement therebetween and can comprise a slip joint 286. The slip joint 286 can permit the intermediate firing shaft portion 222 of the firing drive 220 to be moved to articulate the surgical end effector 700 without moving, or at least substantially moving, the firing beam 280. Once the surgical end effector 700 has been suitably oriented, the intermediate firing shaft portion 222 can be advanced distally until a proximal sidewall of the longitudinal slot 223 comes into contact with the tab 284 in order to advance the firing beam 280 and fire a staple cartridge that may be supported in the end effector 700. As can be further seen in FIG. 4, the shaft spine 210 has an elongate opening or window 213 therein to facilitate assembly and insertion of the intermediate firing shaft portion 222 into the shaft frame 210. Once the intermediate firing shaft portion 222 has been inserted therein, a top frame segment 215 may be engaged with the shaft frame 212 to enclose the intermediate firing shaft portion 222 and firing beam 280 therein. Further description of the operation of the firing member 220 may be found in U.S. patent application Ser. No. 13/803,086, now U.S. Patent Application Publication No. 2014/0263541.

Further to the above, the illustrated shaft assembly 200 includes a clutch assembly 400 which can be configured to selectively and releasably couple the articulation driver 230 to the firing member 220. In one form, the clutch assembly 400 includes a lock collar, or sleeve 402, positioned around the firing member 220 wherein the lock sleeve 402 can be rotated between an engaged position in which the lock sleeve 402 couples the articulation driver 230 to the firing member 220 and a disengaged position in which the articulation driver 230 is not operably coupled to the firing member 200. When lock sleeve 402 is in its engaged position, distal movement of the firing member 220 can move the articulation driver 230 distally and, correspondingly, proximal movement of the firing member 220 can move the proximal articulation driver 230 proximally. When lock sleeve 402 is in its disengaged position, movement of the firing member 220 is not transmitted to the proximal articulation driver 230 and, as a result, the firing member 220 can move independently of the proximal articulation driver 230. In various circumstances, the proximal articulation driver 230 can be held in position by the articulation lock 350 when the proximal articulation driver 230 is not being moved in the proximal or distal directions by the firing member 220.

As can be further seen in FIG. 4, the lock sleeve 402 can comprise a cylindrical, or an at least substantially cylindrical, body including a longitudinal aperture 403 defined therein configured to receive the firing member 220. The lock sleeve 402 can comprise diametrically-opposed, inwardly-facing lock protrusions 404 and an outwardly-facing lock member 406. The lock protrusions 404 can be configured to be selectively engaged with the firing member 220. More particularly, when the lock sleeve 402 is in its engaged position, the lock protrusions 404 are positioned within a drive notch 224 defined in the firing member 220 such that a distal pushing force and/or a proximal pulling force can be transmitted from the firing member 220 to the lock sleeve 402. When the lock sleeve 402 is in its engaged position, a second lock member 406 is received within a drive notch 232 defined in the proximal articulation driver 230 such that the distal pushing force and/or the proximal pulling force applied to the lock sleeve 402 can be transmitted to the proximal articulation driver 230. In effect, the firing member 220, the lock sleeve 402, and the proximal articulation driver 230 will move together when the lock sleeve 402 is in its engaged position. On the other hand, when the lock sleeve 402 is in its disengaged position, the lock protrusions 404 may not be positioned within the drive notch 224 of the firing member 220 and, as a result, a distal pushing force and/or a proximal pulling force may not be transmitted from the firing member 220 to the lock sleeve 402. Correspondingly, the distal pushing force and/or the proximal pulling force may not be transmitted to the proximal articulation driver 230. In such circumstances, the firing member 220 can be slid proximally and/or distally relative to the lock sleeve 402 and the proximal articulation driver 230.

As can also be seen in FIG. 4, the elongate shaft assembly 200 further includes a switch drum 500 that is rotatably received on the closure tube 260. The switch drum 500 comprises a hollow shaft segment 502 that has a shaft boss 504 formed thereon for receive an outwardly protruding actuation pin 410 therein. In various circumstances, the actuation pin 410 extends through a slot 267 into a longitudinal slot 408 provided in the lock sleeve 402 to facilitate axial movement of the lock sleeve 402 when it is engaged with the proximal articulation driver 230. A rotary torsion spring 420 is configured to engage the shaft boss 504 on the switch drum 500 and a portion of the nozzle housing 203 to apply a biasing force to the switch drum 500. The switch drum 500 can further comprise at least partially circumferential openings 506 defined therein which, referring to FIGS. 5 and 6, can be configured to receive circumferential mounts extending from the nozzle portions 202, 203 and permit relative rotation, but not translation, between the switch drum 500 and the proximal nozzle 201. The mounts also extend through openings 266 in the closure tube 260 to be seated in recesses in the shaft spine 210. However, rotation of the nozzle 201 to a point where the mounts reach the end of their respective slots 506 in the switch drum 500 will result in rotation of the switch drum 500 about the shaft axis SA-SA. Rotation of the switch drum 500 will ultimately result in the rotation of the actuation pin 410 and the lock sleeve 402 between its engaged and disengaged positions. Thus, in essence, the nozzle 201 may be employed to operably engage and disengage the articulation drive system with the firing drive system in the various manners described in further detail in U.S. patent application Ser. No. 13/803,086, now U.S. Patent Application Publication No. 2014/0263541.

As also illustrated in FIGS. 3 and 4, the elongate shaft assembly 200 can comprise a slip ring assembly 600 which can be configured to conduct electrical power to and/or from the end effector 700 and/or communicate signals to and/or from the surgical end effector 700, for example. The slip ring assembly 600 can comprise a proximal connector flange 604 mounted to a chassis flange 242 extending from the chassis 240 and a distal connector flange 601 positioned within a slot defined in the shaft housings 202, 203. The proximal connector flange 604 can comprise a first face and the distal connector flange 601 can comprise a second face which is positioned adjacent to and movable relative to the first face. The distal connector flange 601 can rotate relative to the proximal connector flange 604 about the shaft axis SA-SA. The proximal connector flange 604 can comprise a plurality of concentric, or at least substantially concentric, conductors 602 defined in the first face thereof. A connector 607 can be mounted on the proximal side of the distal connector flange 601 and may have a plurality of contacts (not shown) wherein each contact corresponds to and is in electrical contact with one of the conductors 602. Such arrangement permits relative rotation between the proximal connector flange 604 and the distal connector flange 601 while maintaining electrical contact therebetween. The proximal connector flange 604 can include an electrical connector 606 which can place the conductors 602 in signal communication with a shaft circuit board 610 mounted to the shaft chassis 240, for example. In at least one instance, a wiring harness comprising a plurality of conductors can extend between the electrical connector 606 and the shaft circuit board 610. U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Patent Application Publication No. 2014/0263552, is incorporated by reference herein in its entirety. U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Patent Application Publication No. 2014/0263551 is incorporated by reference herein in its entirety. Further details regarding slip ring assembly 600 may be found in U.S. patent application Ser. No. 13/803,086, now U.S. Patent Application Publication No. 2014/0263541.

As discussed above, the elongate shaft assembly 200 can include a proximal portion which is fixably mounted to the handle 14 and a distal portion which is rotatable about a longitudinal shaft axis SA-SA. The rotatable distal shaft portion can be rotated relative to the proximal portion about the slip ring assembly 600, as discussed above. The distal connector flange 601 of the slip ring assembly 600 can be positioned within the rotatable distal shaft portion. Moreover, further to the above, the switch drum 500 can also be positioned within the rotatable distal shaft portion. When the rotatable distal shaft portion is rotated, the distal connector flange 601 and the switch drum 500 can be rotated synchronously with one another. In addition, the switch drum 500 can be rotated between a first position and a second position relative to the distal connector flange 601. When the switch drum 500 is in its first position, the articulation drive system (i.e., the proximal articulation driver 230) may be operably disengaged from the firing drive system and, thus, the operation of the firing drive system may not articulate the end effector 700 of the shaft assembly 200. When the switch drum 500 is in its second position, the articulation drive system (i.e., the proximal articulation driver 230) may be operably engaged with the firing drive system and, thus, the operation of the firing drive system may articulate the end effector 700 of the shaft assembly 200. When the switch drum 500 is moved between its first position and its second position, the switch drum 500 is moved relative to distal connector flange 601. In various instances, the shaft assembly 200 can comprise at least one sensor that is configured to detect the position of the switch drum 500.

Referring again to FIG. 4, the closure tube assembly 260 includes a double pivot closure sleeve assembly 271. According to various forms, the double pivot closure sleeve assembly 271 includes an end effector closure sleeve 272 that includes upper and lower distally projecting tangs 273, 274. An upper double pivot link 277 includes upwardly projecting distal and proximal pivot pins that engage respectively an upper distal pin hole in the upper proximally projecting tang 273 and an upper proximal pin hole in an upper distally projecting tang 264 on the closure tube 260. A lower double pivot link 278 includes upwardly projecting distal and proximal pivot pins that engage respectively a lower distal pin hole in the lower proximally projecting tang 274 and a lower proximal pin hole in the lower distally projecting tang 265.

As can be seen in FIGS. 5 and 6, the surgical end effector 700 includes an elongate channel 702 that is configured to operably support a surgical staple cartridge 800 therein. The elongate channel 702 has a proximal end portion 704 that includes two upstanding lateral walls 706. The surgical end effector 700 further includes an anvil 710 that has an anvil body 712 that has a staple-forming undersurface 714 formed thereon. The proximal end 716 of the anvil body 712 includes a laterally protruding anvil trunnion 718. A trunnion slot 708 is provided in each lateral wall 706 of the elongate channel 702 for receiving a corresponding one of the anvil trunnions 718 therein. Such arrangement serves to movably affix the anvil 710 to the elongate channel 702 for selective pivotable travel between open and closed or clamped positions. The anvil 710 includes a tab 720 that is engageable with a horseshoe-shaped slot 722 in the end effector closure sleeve 272. When the closure tube 260 and, more particularly, the end effector closure sleeve 272, is moved distally, a side wall of the slot 722 can engage the tab 720 to rotate the anvil 710 toward the elongate channel 702. To open the anvil 710, the closure tube 260 and, more particularly, the end effector closure sleeve 272 is moved in the proximal direction. In doing so, a central tab portion defined by the horseshoe shaped slot 722 cooperates with the tab 720 on the anvil 710 to pivot the anvil 710 to an open position. Other anvil and closure arrangements are disclosed in U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS, filed Jun. 18, 2015, the entire disclosure of which is hereby incorporated by reference herein.

Referring now to FIGS. 6-8, an exemplary staple cartridge 800 comprises a cartridge body 802 that may be molded for example, from a polymer material and be configured to be removably retained within the elongate channel 702. The staple cartridge body 802 includes a centrally disposed elongate slot 804 that is configured to receive a tissue cutting member 750 therein. A plurality of staple cavities 810 a, 810 b, 810 c are arranged in the cartridge body 802 on each side of the elongate slot 804. In the embodiment depicted in FIGS. 6-8, the staple cavities 810 a, 810 b, 810 c are generally oriented in a “herringbone-like” pattern. Each staple cavity 810 a, 810 b, 810 c is configured to removably store a staple therein, although it is possible that some staple cavities 810 a, 810 b, 810 c may not contain a staple stored therein. As will be discussed in further detail below, the staple cartridge 800 further comprises a plurality of staple drivers 900 a, 900 b that are movably positioned within the cartridge body 802 in conjunction with corresponding staple cavities. Each staple driver 900 a, 900 b is configured to support one or more staples thereon and/or lift the staples out of their respective staple cavities 810 a, 810 b, 810 c at the same time, or concurrently when contacted by a sled or camming actuator 760.

Referring to FIG. 6, as indicated above, the end effector 700 can include a tissue cutting member 750 that is configured to incise tissue captured between the staple cartridge 800 and the anvil 710. In the illustrated example, the tissue cutting member 750 is coupled to or integrally formed on a distal end of the firing beam 280 and is oriented for movement within the elongate slot 804. Distal advancement of the firing beam 280 will therefore result in the distal advancement of the tissue cutting member 750 within the elongate slot 804 in the staple cartridge body 802. The anvil 710 also includes a longitudinal slot configured to at least partially receive a portion of the tissue cutting member 750; however, embodiments are envisioned in which only one of the cartridge 800 and the anvil 710 includes a slot configured to receive a tissue cutting member. In the illustrated embodiment, the tissue cutting member 750 comprises at least one first projection 752 extending therefrom which is configured to engage the anvil 710 and at least one second projection 754 that is configured to engage the elongate channel 702. The projections 752 and 754 can position the anvil 710 and the staple cartridge 800 relative to one another. As the tissue cutting member 750 is advanced distally, the projections 752 and 754 can position the anvil 710 and set the tissue gap between the staple forming undersurface 714 of the anvil 710 and the deck surface 816 of the staple cartridge 800 supported in the elongate channel 702.

As can be seen in FIG. 6, for example, the sled or camming actuator 760 is configured to be engaged by the tissue cutting member 750 as the tissue cutting member 750 is distally driven through the staple cartridge 800 by the firing beam 280. In other arrangements, however, the sled 760 and tissue cutting member 750 may be formed as a single component. In still other arrangements that do not employ a tissue cutting member, the firing beam may contact the sled or camming member or be integrally formed therewith. The sled 760 comprises one or more ramp or camming surfaces which are configured to drivingly contact or slide under the staple drivers 900 a, 900 b and lift the staple drivers 900 a, 900 b upwardly toward the deck surface 816 of the staple cartridge 800. In the illustrated embodiment, the sled 760 comprises four ramp or camming surfaces or camming members 762, 764, 766 and 768. As will be discussed in further detail below, the sled 760 is movable from a proximal end 803 of the staple cartridge 800 toward a distal end 811 of the cartridge 800 to sequentially lift the staple drivers 900 a, 900 b in their respective “driver arrays” on each side of the elongate slot 804. When the drivers 900 a, 900 b are driven toward the deck surface 816 by the sled 760, the staple drivers 900 a, 900 b lift the staples supported thereon toward the staple forming undersurface 714 of the anvil 710. As the sled 760 is progressed distally, the staples are driven against the staple-forming undersurface 714 of the anvil 710 and are ejected from the staple cavities 810 a, 810 b, 810 c by the staple drivers 900 a, 900 b. The staple cartridge 800 can further comprise a support pan 780 attached thereto which extends around the bottom of the staple cartridge body 802 and retains the staple drivers 900 a, 900 b, the staples, and/or the sled 760 within the cartridge 800.

As indicated above, in the illustrated exemplary embodiment, the surgical instrument 10 includes an articulation drive system 500, which when actuated can articulate the end effector 700 about an articulation joint 270. When the proximal articulation driver 230 is pushed in a first direction, the end effector 700 can be rotated in a first direction and, when the proximal articulation driver 230 is pushed in a second direction, the end effector 700 can be rotated in a second, or opposite, direction. In other embodiments, the end effector is not capable of articulation. Referring now to FIG. 6, the illustrated end effector 700 includes an end effector mounting assembly 790 that is adapted to be pivotally mounted to, for example, a portion of the articulation lock 350 (FIG. 4) that is configured to be rotatably received within the mounting hole 792 in the end effector mounting assembly 790. In the illustrated embodiment, the end effector mounting assembly 790 is mounted to the elongate channel 702 via a spring pin 796 which extends through apertures 705 defined in the elongate channel 702 and the end effector mounting assembly 790. As described in further detail in U.S. Patent Application Publication No. 2014/0263541, which has been herein incorporated by reference in its entirety, the articulation lock 350 may be movable between a first, locked or engaged, position in which the lock is engaged with the end effector mounting assembly 790 and a second, or unlocked or disengaged, position. When the articulation lock 350 is in its engaged or locked position, the articulation lock 350 can hold the end effector 700 in position. When the articulation lock 350 is in its disengaged position, the end effector 700 can be rotated about the articulation joint 270. Other articulation arrangements are disclosed in U.S. patent application Ser. No. 14/314,788, entitled ROBOTICALLY-CONTROLLED SHAFT BASED ROTARY DRIVE SYSTEMS FOR SURGICAL INSTRUMENTS, which was filed on Jun. 25, 2014, now U.S. Patent Application Publication No. 2014/0305993, and which is herein incorporated by reference in its entirety. Still other articulation arrangements are disclosed in U.S. Patent Application Publication No. 2013/0168435, entitled SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, which was filed on Feb. 26, 2013, which is hereby incorporated by reference herein in its entirety.

Turning now to FIGS. 7 and 8, the staple cavities 810 a, 810 b, 810 c of the staple cartridge 800 open through the deck surface 816 and can be positioned and arranged such that the staples stored in the staple cavities 810 a, 810 b, 810 c are deployed as part of an extensible or “flexible” or “elastic” staple line. The staple cavities 810 a, 810 b, 810 c are arranged in a “staple cavity array” generally designated as 806. In at least one arrangement, the staple cavity array 806 comprises a first row 807 of staple cavities 810 a which removably stores a first row of staples. The first row 807 of staple cavities 810 a extends along a first longitudinal axis 812 a adjacent the elongate slot 804. The staple cavity array 806 also comprises a second row 808 of staple cavities 810 b which removably stores a second row of staples. The second row 808 of staple cavities 810 b extends along a second longitudinal axis 812 b adjacent the first row 807 of staple cavities 810 a. The staple cavity array 806 further comprises a third row 809 of staple cavities 810 c which removably store a third row of staples. The third row 809 of staple cavities 810 c extends along a third longitudinal axis 812 c adjacent the second row 808 of staple cavities 810 b. The first longitudinal axis 812 a is parallel, or at least substantially parallel, to the second longitudinal axis 812 b; however, other arrangements are possible in which the first longitudinal axis 812 a is not parallel to the second longitudinal axis 812 b. The second longitudinal axis 812 b is parallel, or at least substantially parallel, to the third longitudinal axis 812 c; however, other arrangements are possible in which the second longitudinal axis 812 b is not parallel to the third longitudinal axis 812 c. The first longitudinal axis 812 a is parallel, or at least substantially parallel, to the third longitudinal axis 812 c; however, other arrangements are possible in which the first longitudinal axis 812 a is not parallel to the third longitudinal axis 812 c. Referring again to FIGS. 7 and 8, the staple cartridge 800 comprises a first portion of the staple cavity array 806 including a first row 807 of staple cavities 810 a, a second row 808 of second staple cavities 810 b, and a third row 809 of third staple cavities 810 c on a first side 805 of the longitudinal slot 804 and a second portion of the cavity array 806 including a first row 810 a, a second row 810 b, and a third row 810 c on a second side 801 of the longitudinal slot 804. The first cavity array portion is a mirror image of the second cavity array portion with respect to the longitudinal slot; however, other arrangements may be utilized.

Still referring to FIG. 7, each of the first staple cavities 810 a is oriented at a first angle 824 a with respect a first reference axis 997 a that is perpendicular to the first longitudinal axis 812 a. Also in the illustrated arrangement, each of the second staple cavities 810 b is oriented at a second angle 824 b with respect to a second reference axis 997 b that is perpendicular to the second longitudinal axis 812 b. In addition, each of the third staple cavities 810 c is oriented at a third angle 824 c with respect to a third reference axis 997 c that is perpendicular to the third longitudinal axis 812 c. The first angle 824 a is different than the second angle 824 b; however, in other embodiments, the first angle 824 a and the second angle 824 b can be the same. The third angle 824 c is different than the second angle 824 b; however, in other embodiments, the third angle 824 c and the second angle 824 b can be the same. The first angle 824 a is the same as the third angle 824 c; however, in other embodiments, the first angle 824 a and the third angle 824 c can be different. In at least one embodiment, angle 824 a may be approximately forty-five (45) degrees (with a range of ±thirty (30) degrees for example); angle 824 b may be approximately fifty (50) degrees (with a range of ±thirty (30) degrees, for example); and angle 824 c may be approximately forty-five (45) degrees with a range of ±thirty (30) degrees, for example).

The staple cartridge 800 is configured to deploy the staple pattern 813 depicted in FIG. 9. The staple cartridge 800 is configured to deploy a first row 817 of staples 820 a along a first longitudinal axis 822 a, a second row 818 of staples 820 b along a second longitudinal axis 822 b, and a third row 819 of staples 820 c along a third longitudinal axis 822 c. In various instances, the staple cartridge 800 is configured to deploy a first row 817 of staples 820 a, a second row 818 of staples 820 b, and a third row 819 of staples 820 c on a first side of a longitudinal incision 826 and a first row 817 of staples 820 a, a second row 818 of staples 820 b, and a third row 819 of staples 820 c on a second side of the longitudinal incision 826. The first rows 817 of staples 820 a can be positioned adjacent the longitudinal incision 826 and the third row 819 of staples 820 c can be positioned furthest away from the longitudinal incision 826. Each second row 818 of staples 820 b can be positioned intermediate a first row 817 of staples 820 a and a third row 819 of staples 820 c.

Further to the above, the first staples 820 a are removably stored in the first staple cavities 810 a, the second staples 820 b are removably stored in the second staple cavities 810 b, and the third staples 820 c are removably stored in the third staple cavities 810 c. The staple cavities 810 a-810 c are configured and arranged to deploy the staples 820 a-820 c in the arrangement depicted in FIGS. 9 and 10. For example, the first staples 820 a are oriented at the first angle 824 a with respect to a first reference axis 999 a that is perpendicular to the first longitudinal axis 822 a. The second staples 820 b are oriented at the second angle 824 b with respect to a second reference axis 999 b that is perpendicular to the second longitudinal axis 822 b. The third staples 820 c are oriented at the third angle 824 c with respect to a third reference axis 999 c that is perpendicular to the third longitudinal axis 822 c.

The first staples 820 a, the second staples 820 b, and the third staples 820 c can be positioned and arranged such that they provide “laterally-overlapping” staple lines. More particularly, referring again to FIG. 9, the second longitudinal row 818 of second staples 820 b is positioned laterally with respect to the first longitudinal row 817 of first staples 820 a such that the second staples 820 b are aligned with the gaps between the first staples 820 a and, similarly, the third longitudinal row 819 of third staples 820 c is positioned laterally with respect to the second longitudinal row 818 of second staples 820 b such that the third staples 820 c are aligned with the gaps between the second staples 820 b. Such an arrangement can limit the flow of blood from the tissue T to the longitudinal incision 826.

Further to the above, the staple pattern disclosed in FIG. 9 comprises six longitudinal rows of staples. Other embodiments are envisioned which comprise less than six rows of staples, such as four rows of staples, for example, or more than six rows of staples, such as eight rows of staples, for example. The first staples 820 a, the second staples 820 b, and the third staples 820 c can comprise any suitable configuration such as, for example, a V-shaped configuration or a U-shaped configuration. A staple comprising a V-shaped configuration can include a base or crown, a first leg extending from a first end of the base or crown, and a second leg extending from a second end of the base or crown, wherein the first leg and the second leg extend in directions which are non-parallel to one another. A staple comprising a U-shaped configuration can include a base or crown, a first leg extending from a first end of the base or crown, and a second leg extending from a second end of the base or crown, wherein the first leg and the second leg extend in directions which are parallel to one another.

With regard to the staple pattern disclosed in FIG. 9, for example, each first staple 820 a comprises a first staple base or crown 827 a (FIG. 12) that has a first proximal staple leg 825 a and a first distal staple leg 823 a protruding therefrom. A staple cartridge 800 configured to deploy the staple pattern 813 disclosed in FIG. 9 can include a proximal end 803 and a distal end 811. The first proximal staple leg 825 a can be closer to the proximal end 803 of the staple cartridge 800 than the first distal staple leg 823 a and, similarly, the first distal staple leg 823 a can be closer to the distal end 811 of the staple cartridge 800 than the first proximal staple leg 825 a. The first crown 827 a of each first staple 820 a can define a first base axis “FBA”. Each of the first proximal staple leg 825 a and the first distal staple leg 823 a can extend from the first base axis FBA. The first staples 820 a can be positioned and arranged such that the first base axes FBA's extend toward the longitudinal cut line 826 and toward the distal end of the staple cartridge 800. Stated another way, the first base axis FBA may be transverse to the elongate slot 804.

With regard to the staple pattern 813 disclosed in FIG. 9, for example, each second staple 820 b comprises a second staple base or crown 827 b (FIG. 12) that has a second proximal staple leg 825 b and a second distal staple leg 823 b protruding therefrom. The second proximal staple leg 825 b can be closer to the proximal end 803 of the staple cartridge 800 than the second distal staple leg 823 b and, similarly, the second distal staple leg 823 b can be closer to the distal end 811 of the staple cartridge 800 than the second proximal staple leg 825 b. The base second crown 827 b of each second staple 820 b can define a second base axis “SBA”. The second proximal staple leg 825 b and the second distal staple leg 823 b can extend from the second base axis SBA. The second staples 820 b can be positioned and arranged such that the second base axes SBA's extend toward the longitudinal incision 826 and toward the proximal end 803 of the staple cartridge 800. In the illustrated example, the second base axes SBA are transverse to the first base axes as well as to the elongate slot 804.

With regard to the staple pattern 813 disclosed in FIG. 9, for example, each third staple 820 c comprises a third base or crown 827 c (FIG. 12) that has a third proximal staple leg 825 c and a third distal staple leg 823 c protruding therefrom. The third proximal staple leg 825 c can be closer to the proximal end 803 of the staple cartridge 800 than the third distal staple leg 823 c and, similarly, the third distal staple leg 823 c can be closer to the distal end 811 of the staple cartridge 800 than the third proximal staple leg 825 c. The third crown 827 c of each third staple 820 c can define a third base axis “TBA”. The third proximal staple leg 825 c and the third distal staple leg 823 c can extend from the third base axis TBA. The third staples 820 c can be positioned and arranged such that the third base axes TBA's extend toward the longitudinal cut line 826 and toward the distal end of the staple cartridge. In the illustrated example, the third base axes TBA are parallel to the first base axes FBA and are transverse to the second base axes SBA as well as to the elongate slot 804. This is but one exemplary embodiment and any suitable arrangement could be utilized.

Further to the above, the first staples 820 a straddle the first longitudinal axis 822 a. See FIG. 9. The first distal legs 823 a of the first staples 820 a are positioned on one side of the first longitudinal axis 822 a and the first proximal legs 825 a are positioned on the other side of the first longitudinal axis 822 a. Stated another way, the legs of the first staples 820 a are offset with respect to the first longitudinal axis 822 a. Alternative embodiments are envisioned in which the first staples 820 a are aligned with or collinear with the first longitudinal axis 822 a. The second staples 820 b straddle the second longitudinal axis 822 b. The second distal legs 823 b of the second staples 820 b are positioned on one side of the second longitudinal axis 822 b and the second proximal legs 825 b are positioned on the other side of the second longitudinal axis 822 b. Stated another way, the legs of the second staples 820 b are offset with respect to the second longitudinal axis 822 b. Alternative embodiments are envisioned in which the second staples 820 b are aligned with or collinear with the second longitudinal axis 822 b.

In the illustrated example, the third staples 820 c straddle the third longitudinal axis 820 c. The third distal legs 823 c of the third staples 820 c are positioned on one side of the third longitudinal axis 820 c and the third proximal legs 825 c are positioned on the other side of the third longitudinal axis 822 c. Stated another way, the legs of the third staples 820 c are offset with respect to the third longitudinal axis 822 c. Alternative embodiments are envisioned in which the third staples 820 c are aligned with or collinear with the third longitudinal axis 822 c. In certain embodiments, a first staple 820 a can comprise a first proximal leg 825 a which is aligned with the second distal leg 823 b of an adjacent second staple 820 b. Similarly, a third staple 820 c can comprise a third proximal leg 825 c which is aligned with the second distal leg 823 b of an adjacent second staple 820 b. In various embodiments, a first staple 820 a can comprise a first proximal leg 825 a which is positioned distally with respect to the second distal leg 823 b of an adjacent second staple 820 b. Similarly, a third staple 820 c can comprise a third proximal leg 825 c which is positioned distally with respect to the second distal leg 823 b of an adjacent second staple 820 b. The row of second staples 820 b is bounded by the row of first staples 820 a and the row of third staples 820 c. A second staple 820 b is bounded on one side by a first staple 820 a and on the other side by a third staple 820 c. More particularly, a first staple 820 a is positioned laterally inwardly with respect to the second proximal leg 825 b of a second staple 820 b and, similarly, a third staple 820 c is positioned laterally outwardly with respect to the second distal leg 823 b of the second staple 820 b. As a result, the first staples 820 a can provide a boundary on one side of the second staples 820 b and the third staples 820 b can provide a boundary on the other side of the second staples 820 b.

A traditional staple pattern 829 is illustrated in FIG. 11. This staple pattern 829 comprises a first row 836 of first staples 830 a positioned along a first longitudinal axis 832 a, a second row 838 of second staples 830 b positioned along a second longitudinal axis 832 b, and a third row 840 of third staples 830 c positioned along a third longitudinal axis 832 c positioned on a first side of a longitudinal incision 835 in the tissue T. The first staples 830 a are aligned, or at least substantially aligned, with the first longitudinal axis 832 a; the second staples 830 b are aligned, or at least substantially aligned, with the second longitudinal axis 832 b; and the third staples 830 c are aligned, or at least substantially aligned, with the third longitudinal axis 832 c. Stated another way, the first staples 830 a are not oriented at an angle with respect to the first longitudinal axis 832 a, the second staples 830 b are not oriented at an angle with respect to the second longitudinal axis 832 b, and the third staples 830 c are not oriented at an angle with respect to the third longitudinal axis 832 c. This traditional staple pattern also comprises a first row 836 of staples 830 a positioned along a first longitudinal axis 832 a, a second row 838 of staples 830 b positioned along a second longitudinal axis 832 b, and a third row 840 of staples 830 c positioned along a third longitudinal axis 832 c positioned on a second, or opposite, side of the longitudinal incision 835.

When a longitudinal tensile force is applied to the tissue T stapled by the staple pattern 829 illustrated in FIG. 11, the tissue T will stretch longitudinally. Moreover, in various instances, the staples 830 a, 830 b and 830 c can translate longitudinally as the tissue T is stretched longitudinally. Such an arrangement can be suitable in many circumstances; however, the staples 830 a, 830 b and 830 c can restrict the stretching and/or movement of the tissue T. In some instances, the tissue T that has been stapled by the staples 830 a, 830 b and 830 c may be far less flexible than the adjacent tissue that has not been stapled. Stated another way, the staple pattern 829 comprising the staples 830 a, 830 b, and 830 c can create a sudden change in the material properties of the tissue. In at least one instance, a large strain gradient can be created within the tissue T as a result of the staple pattern which, in turn, can create a large stress gradient within the tissue T.

When the staples 830 a-830 c are ejected from a staple cartridge, the legs of the staples can puncture the tissue T. As a result, the staple legs create holes in the tissue. Various types of tissues are resilient and can stretch around the staple legs as the staple legs pass through the tissue. In various instances, the resiliency of the tissue can permit the tissue to stretch and resiliently return toward the staple legs to reduce or eliminate gaps present between the tissue and the staple legs. Such resiliency or elasticity can also permit the tissue to stretch when a stretching force is applied to the tissue; however, such resiliency can be inhibited by certain staple patterns. In at least one instance, the staple pattern 829 depicted in FIG. 11 can inhibit the longitudinal stretching of the tissue. When a longitudinal stretching force is applied to the tissue stapled by the staple pattern of FIG. 11, the tissue may begin to pull away from the staple legs and create gaps therebetween. In some instances, especially in bariatric resection applications, such gaps can result in increased bleeding from the stomach tissue. In certain instances, especially in lung resection applications, air leaks can result in the lung tissue, for example.

The staple pattern 813 depicted FIGS. 9 and 10 is more flexible or elastic than “traditional” staple pattern 829 arrangements of the type depicted in FIG. 11. For example, when a longitudinal tensile force is applied to the tissue T, referring now to FIG. 10, the staples 820 a, 820 b, and 820 c can, one, translate longitudinally as the tissue is stretched longitudinally and/or, two, rotate as the tissue is stretched longitudinally. Moreover, the compliant staple pattern 813 depicted in FIG. 9 can reduce or eliminate the gaps between the staple legs and the tissue T when a longitudinal stretching force is applied to the tissue and, as a result, reduce the bleeding and/or air leaks between the staple legs and the tissue. The staple pattern 813 depicted in FIG. 9 is depicted in an unstretched condition. When the tissue stapled by the staple pattern depicted in FIG. 9 is stretched longitudinally, the staples can move longitudinally with the tissue and/or rotate within the tissue, as illustrated in FIG. 10. U.S. patent application Ser. No. 14/498,121, entitled FASTENER CARTRIDGE FOR CREATING A FLEXIBLE STAPLE LINE, filed Sep. 26, 2014, the entire disclosure of which is hereby incorporated by reference herein discloses various advantages as well as other variations of the elastic or compliant staple lines described above.

As indicated above, the staples 820 a, 820 b, 820 c are supported on corresponding drivers 900 a, 900 b that are movably supported in cavities formed in the cartridge body 802. To achieve staples with consistent “formed” shapes, it may be desirable for each of the staples to exit out of their respective cavity so that the staple legs thereof are generally perpendicular to the corresponding portion of the staple forming undersurface 714 of the anvil 710. As indicated above, the staple drivers on which the staples are supported are driven upwardly when they are drivingly contacted by the corresponding ramps or camming members of the distally-moving sled or camming member 760. Because the sled ramps are moving in directions that are essentially transverse to the direction in which the drivers are moving, the driving motion applied by the sled ramps to the drivers could, at times, skew a staple driver within its respective cavity as it is driven upward therein. Such skewing of the staple driver(s) may undesirably result in one, an increase in the force required to drive the firing beam and/or two result in the skewing of the staples as they are ejected from the cartridge body which could ultimately lead to inconsistently formed staples or even malformed staples. Thus, it may be desirable to employ staple driver arrangements and corresponding cartridge body arrangements that afford sufficient amounts of support to the staple drivers as they are drivingly contacted by the sled ramps.

FIGS. 12-14 illustrate a staple driver 900 a according to at least one embodiment of the present invention. In at least one arrangement, the staple drivers 900 b may be mirror images of staple drivers 900 a. As can be seen in FIG. 12, one staple driver 900 a can support three staples 820 a, 820 b, 820 c thereon. The staple driver 900 a includes a first or innermost staple support portion 910 that is configured to support a first staple 820 a thereon, a second or central staple support portion 930 that is configured to support a second staple 820 b thereon and a third or outermost staple support portion 950 that is configured to support a third staple 820 c thereon. As used in this context, the term “innermost” refers to the staple support portion that is closest to the elongate slot 804 in the cartridge body 802 and the term “outermost” refers to the staple support portion that is the farthest away from the elongate slot 804.

As can be seen in FIG. 12, the first staple support portion 910 comprises a first distal support column 914 and a first proximal support column 918. The first staple support portion 910 further includes a first distal support cradle 916 and a first proximal support cradle 920 for supporting portions of the first staple crown 827 a. As can be further seen in FIG. 12, when the first staple crown 827 a of the first staple 820 a is supported on the support cradles 916 and 920, the first distal leg 823 a is essentially axially aligned with the first distal support column 914 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 918.

Still referring to FIG. 12, the driver 900 a further comprises second staple support portion 930 that comprises a second distal support column 934 and a second proximal support column 938. The second staple support portion 930 further includes a second distal support cradle 936 and a second proximal support cradle 940 for supporting portions of the second staple crown 827 b therein. As can also be seen in FIG. 12, when the second staple crown 827 b of the second staple 820 b is supported in the second cradles 936, 940, the second distal leg 823 b is essentially axially aligned with the second distal support column 934 and the second proximal leg 825 b is essentially axially aligned with the second proximal support column 938.

As can also be seen in FIG. 12, the driver 900 a comprises a third staple support portion 950 that includes a third distal support column 954 and a third proximal support column 958. The third staple support portion 950 further includes a third distal support cradle 956 and a third proximal support cradle 960 that are configured to support portions of the third staple crown 827 c of the third staple 820 c therein. As can be seen in FIG. 12, when the third crown 827 c of the third staple 820 c is supported in the third cradles 956, 960, the third distal leg 823 c is essentially axially aligned with the third distal support column 954 and the third proximal leg 825 c is essentially axially aligned with the third proximal support column 958.

Still referring to FIGS. 12-14, in at least one arrangement the first staple support portion 910 is coupled to the second staple support portion 930 by a first or distal connection member 970. The first connection member 970 includes a first cam portion that has a first camming surface or ramp 974 formed on the underside thereof. The second staple support portion 930 is likewise connected to the third staple support portion 950 by a second or proximal connection member 980. A second cam member 982 protrudes from or is attached to the third staple support portion 950 and has a second camming surface or ramp 984 formed thereon. In the illustrated arrangement, the first and second camming surfaces 974, 984 are formed with the same angle and are essentially parallel to each other. In other arrangements, however, the first and second camming surfaces 974, 984 may differ from each other. The camming angle of the first and second camming surface 974, 984 may relate to the cam angles of the corresponding ramp or camming surfaces of the sled 760. In at least one embodiment, the staple driver 900 a (and 900 b) is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the staple driver 900 a (and 900 b) may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

FIG. 15 is a bottom perspective view of a portion of one form of the surgical staple cartridge body 802. As indicated above, in at least one embodiment, the cartridge body 802 includes an elongate slot 804 that may be centrally disposed in the body 802. In the embodiment depicted in FIG. 15, for example, the elongate slot 804 bifurcates the cartridge body 802 into two body portions 850, 870 and extends along the centrally-disposed cartridge axis “CA”. As can be seen in that Figure, the first body portion 850 includes a first cartridge wall portion 852 that includes first support grooves or slots 854 that are each arranged on a corresponding first slot axis “FSA” that is transverse to the cartridge axis CA. The first body portion 850 further includes a second cartridge wall portion 856 that contains second support grooves or slots 858 therein that are each arranged on a corresponding second slot axis “SSA” that is transverse to the cartridge axis CA. Located between the first cartridge wall portion 852 and the second cartridge wall portion 856 are a plurality of spaced, staple driver guides 860. In at least one arrangement, the staple driver guides 860 are integrally formed with one or both of the cartridge wall portions 852, 856 in the cartridge body 802. In other arrangements, the staple driver guides 860 are attached to the wall portions of the cartridge body 802. Each staple driver guide 860 may be configured to slidably interlock with or, stated another way, slidably support two adjacent staple drivers 900 a. See FIG. 17.

Referring now to FIGS. 16 and 17, in at least one arrangement, each of the staple drivers 900 a includes opposed, hooked shaped slots 901, 903 that are configured to be “hookingly engaged” by corresponding opposed hook-shaped portions 862, 864, respectively of the staple driver guide 860. The hook-shaped portions 862 are configured to slidably support the first proximal support column 918 of a corresponding staple driver 900 a and the hook-shaped portions 864 are configured to slidably support a third distal support column 954 of a corresponding staple driver 900 a. In addition, the staple driver guide 860 further includes a proximal slot 863 that is configured to slidably support the second distal support column 934 of a corresponding staple driver 900 a as well as a distal slot 868 that is configured to slidably support the second proximal support column 938 of the corresponding staple driver 900 a. Thus, each staple driver 900 a that is in sliding engagement with a corresponding staple driver guide 860 is slidably movable relative to the staple driver guide 860 when the staple driver 900 a is drivingly contacted by the sled ramps or camming surfaces 762, 764.

Referring again to FIG. 15, the second body portion 870 includes a primary cartridge wall portion 872 that includes primary staple leg grooves or slots 874 therein that are each arranged on a corresponding primary slot axis “PSA” that is transverse to the cartridge axis CA. The second body portion further includes a secondary cartridge wall portion 876 that contains second support grooves or slots 878 therein that are each oriented on a corresponding secondary slot axis SDSA that is transverse to the cartridge axis CA. Located between the primary cartridge wall portion 872 and the secondary cartridge wall portion 876 are a plurality of other spaced driver guides 860 that are each configured to slidably interlock with two adjacent staple drivers 900 b which may be mirror images of staple drivers 900 a in the manner described above. Thus, each staple driver 900 b that is in slidable engagement with a corresponding driver guide 860 is slidably movable relative to the driver guide 860 when the staple driver 900 b is drivingly contacted by the sled ramps or camming members 766, 768. See FIG. 6.

In the illustrated embodiment, staple drivers 900 a are arranged in first “staple driver array” generally designated as 905 a as shown in FIGS. 16 and 17. When the staple drivers 900 a are arranged as shown in FIGS. 16 and 17, each staple driver 900 a may be in slidable engagement with two corresponding staple guides 860. See FIG. 17. In addition, the first distal support column 914 of each staple driver 900 a may be slidably received within a corresponding first support groove or slots 854 in the first cartridge wall portion 852. See FIGS. 8 and 15. Likewise, the third proximal support column 958 of each staple driver 900 a may be slidably received within a corresponding second support groove or slot 858 in the second cartridge wall portion 856. Thus, each of the support columns of the staple driver 900 a are slidably supported by a corresponding staple driver guide 860 or they are supported by the corresponding cartridge wall portion. Such arrangement may serve to prevent any skewing of the support columns when the staple driver is driven upward within the cartridge body.

Referring again to FIG. 16, it can be seen that each of the first cam portions 972 of the staple drivers 900 a are aligned along a first cam axis “FCA”. Thus, in at least one embodiment, each of the first camming surfaces 974 is axially aligned on the first cam axis FCA. Also, each of the second cam members 982 of the staple drivers 900 a is axially aligned along a second cam axis “SCA”. Thus, each of the second camming surfaces 984 of the staple drivers 900 a is axially aligned along the second cam axis SCA. In at least one arrangement, for example, the cam axes FCA and SCA are parallel to each other as well as to the elongate slot 804 (represented in segmented lines in FIG. 16) in the staple cartridge. Also in the illustrated staple driver array 905 b, each of the first cam members 972 of the staple drivers 900 b are aligned along a primary first cam axis “PCA”. Thus, in at least one embodiment, each of the first camming surfaces 974 of the staple drivers 900 b are axially aligned on the primary cam axis PCA. Also, each of the second cam members 982 of the staple drivers 900 b are all axially aligned along a secondary cam axis “SDCA”. Thus, each of the second camming surfaces 984 of the staple drivers 900 b are axially aligned along the secondary cam axis SDCA.

FIGS. 18 and 19 illustrate the position of the sled or camming actuator 760 relative to the staple drivers 900 a, 900 b. As can be seen in FIG. 18, in the array 905 a of staple drivers 900 a, the ramp or camming member 764 is aligned with the second cam axis SCA. The ramp surface or camming member 762 is aligned with the first cam axis FCA. The ramp or camming member 766 is aligned on the primary cam axis PCA and the ramp or camming member 768 is aligned with the secondary cam axis SDCA. Thus, the ramp or camming member 764 is situated to proceed under a portion of each of the crowns 827 c of staples 820 c that are supported on the drivers 900 a. The ramp or camming surface 762 is situated to proceed under a portion of each of the crowns 827 c of staples 820 a that are supported on the drivers 900 a. Likewise, in the array 905 b of the staple drivers 900 b, the ramp or camming member 766 is situated to proceed under a portion of the crowns 827 a of each of the staples 820 a supported on the drivers 900 b. The ramp or camming member 768 is situated to proceed under a portion of the crown 827 c of each of the staples 820 c supported on the drivers 900 b. Stated another way, none of the ramps or camming members 764, 762, 766, 768 are aligned with any of the staple legs of the staples 820 a, 820 b, 820 c that are supported on the drivers 900 a, 900 b. Such arrangement therefore enables the third proximal support columns 958 of each of the staple drivers 900 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. In addition, the first distal support columns 914 of each of the staple drivers 900 a are slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. Likewise, each of the support columns 918, 934, 938, 954 is also slidably supported in corresponding driver guides 860 that are formed in or attached to the cartridge body 802. Each of the driver guides 860 may have the same height or similar height as the heights of the wall portions 852, 856.

Referring to FIG. 19 for example, the first and second cartridge wall portions 852, 856 (not shown in FIG. 19) have a height represented by “H”. The staple driver guides 860 may have the same or similar heights “H”. This height may also essentially comprise the height of the cartridge body 802 in at least some embodiments. Other embodiments may employ a “stepped deck” which is a deck surface that has more than one planar portion that have different heights which may be measured from the bottom of the cartridge body for example. In FIG. 19, element 816 may represent the staple deck surface (or at least one staple deck surface in embodiments employing a stepped deck) and 781 may represent a surface upon which the staple drivers 900 a, 900 b sit when they are in an unactuated orientation within the cartridge body. For example, element number 781 may represent the upper surface of the support pan 780. See FIG. 6. In at least one arrangement, the driver guides 860 may also have a height that is equal to or nearly equal to height “H” of the cartridge wall portions 852, 856. Thus, the support columns of each driver 900 a, 900 b are essentially slidably supported throughout their entire path of travel (distance “H”) when they are driven upward in the cartridge body when contacted by the ramps or camming members on the sled 760. In other embodiments, the support columns of each driver 900 a, 900 b are each supported for a distance or height that is at least (0.134 inch staple+at least 0.066 inch driver (0.2 inches total) for a staple cartridge that may be used to staple lung tissue for example). Stated another way, the driver can be advanced a distance that is at least as long as the height of the staple (e.g., height of 820). The staple crown is “ejected” from the staple pocket in the cartridge to prevent tissue from being stuck between the driver and the cartridge deck in its fully advanced state. Such feature may help to avoid the staple drivers 900 a, 900 b from skewing during actuation which may reduce the likelihood of the formation of malformed staples.

When the surgical instrument is “fired” or, stated another way, when the firing drive system 80 is actuated to drive the firing beam 280 distally, the tissue cutting member 750 contacts the sled or camming member 760 and drives the camming member 760 distally through the staple cartridge 800. As can be seen in FIG. 16, the camming members 982 of the staple driver 900 a are located “inboard” (i.e., closer to the elongate slot 804) from the support columns 958 (and the staple legs 825 c supported thereon). Likewise, the camming members 982 of the staple drivers 900 b are located inboard of the support columns 958 of those staple drivers 900 b and the staple legs 825 c supported thereon. Such arrangements permit those support columns 958 to be completely slidably supported through their entire range of upward travel by the corresponding wall portions 856, 876 of the staple cartridge. In addition, the support columns 934, 938, 918, 954 are supported through their entire range of upward travel by the corresponding staple driver guides 860 formed in the cartridge body 802. Likewise the support column 914 of each of the staple drivers 900 a, 900 b are slidably supported in the corresponding wall portions 852, 872 of the cartridge body 802 through their entire range of upward travel.

Still referring to FIGS. 16 and 17, the driver array 905 a comprises a plurality of staple drivers 900 a that are each configured to support three staples 820 a, 820 b, 820 c thereon. Of course during use, each driver 900 a may actually support one, two or all three of such staples. On each staple driver 900 a, staple 820 a lies along axis FBA. Stated more precisely, the staple crown 827 a of staple 820 a lies along axis FBA. Staple 820 c lies along axis TBA. Stated more precisely, the staple crown 827 c of staple 820 c lies along the third base axis TBA. In at least one arrangement axes FBA and TBA are parallel to each other. Staple 820 b is centrally supported between staples 820 a and 820 c and lies along an axis SBA. Stated more precisely, the staple crown of 827 b lies along the second base axis SBA. In the illustrated arrangement, SBA is transverse to axes FBA and TBA. Stated another way, the staple driver 900 a is configured to support two surgical staples that are parallel to each other or extend in the same direction and one staple that is transverse to the other two staples or extends in another direction that differs from the directions in which the other two staples extend. In the illustrated arrangement, when the staple drivers 900 a, 900 b are all operably supported in the staple cartridge 800, all of the axes FBA, SBA, TBA are each transverse to the elongate slot 804.

As can be appreciated from reference to FIG. 16, when the staple drivers 900 a are all operably supported in the staple cartridge in the staple driver array 905 a, the staple drivers 900 a form a first longitudinal row 1200 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1200 a extend in a first direction as was described above. Likewise, the staple drivers 900 a form a second longitudinal row 1202 a of staples 820 b that are adjacent the first longitudinal row 1200 a. The staples 820 b in the second longitudinal row 1202 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1200 a. In addition, the staple drivers 900 a form a third longitudinal row 1204 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 1204 a is adjacent to the second longitudinal row 1202 a.

Still referring to FIG. 16, when the staple drivers 900 b are all operably supported in the staple cartridge in the staple driver array 905 b, the staple drivers 900 b form a first longitudinal row 1200 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1200 b extend in a first direction as was described above. Likewise, the staple drivers 900 b form a second longitudinal row 1202 b of staples 820 b that are adjacent the first longitudinal row 1200 b. The staples 820 b in the second longitudinal row 1202 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1200 a. In addition, the staple drivers 900 b form a third longitudinal row 1204 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 1204 b is adjacent to the second longitudinal row 1202 b.

Other staple driver arrays 990 a, 990 b are illustrated in FIGS. 20 and 21. As can be seen in those Figures, the staple driver array 990 a employs a distal staple driver 1000 a and a proximal staple driver 1100 a in addition to a plurality of the staple drivers 900 a. Likewise, the staple driver array 990 b includes a distal staple driver 1000 b and a proximal staple driver 1100 b. Distal staple driver 1000 b may essentially be a mirror image of distal staple driver 1000 a and proximal staple driver 1100 b may essentially be a mirror image of proximal staple driver 1100 a. FIGS. 22-24 illustrate one exemplary form of a distal staple driver 1000 a with it being understood that, in at least one arrangement, the distal staple driver 1000 b essentially contains the same features as a distal staple driver 1000 a, but is a mirror image thereof. Each distal staple driver 1000 a, 1000 b includes a distal staple support portion 1010 that is configured to support a corresponding distal most staple 820 cd thereon. As can be seen in FIGS. 22-24, the distal staple support portion 1010 comprises a distal support column 1014 and a proximal support column 1018. The distal staple support portion 1010 further includes a distal support cradle 1016 and a proximal support cradle 1020 for supporting portions of the staple crown 827 c of the corresponding distal staple 820 cd. When the staple crown 827 c of the distal staple 820 cd is supported on the support cradles 1016 and 1020, the first distal leg 823 c of the staple 820 cd is essentially axially aligned with the first distal support column 1016 and the first proximal leg 825 c is essentially axially aligned with the first proximal support column 1018. In at least one arrangement, the distal staple drivers 1000 a, 1000 b include a distal connection member 1070. The distal connection member 1070 is configured to slidably engage the corresponding distal-most driver guide (designated as 860D in FIG. 21).

In at least one arrangement, the distal connection member 1070 includes a hook-shaped distal slot 1072 that is configured to be “hookingly engaged” by the hook-shaped portion 864 on the corresponding distal-most driver guide 860D. In addition, the distal connection member 1070 may include a projection 1074 that is configured to be slidably received within a corresponding slot 868 in the distal most driver guide 860D. See FIG. 21. Thus, each distal staple driver 1000 a, 1000 b is slidably engaged with a corresponding driver guide 860. In addition, in the array 990 a of staple drivers 900 a, 1000 a, the proximal support column 1018 of the distal staple driver 1000 a may be slidably received within a corresponding second support groove or slot 858 in the second cartridge wall portion 856. Likewise, the proximal support column 1018 of the distal staple driver 1100 b may be slidably received within a corresponding second support groove or slot 878 in the secondary cartridge wall portion 876. As can also be seen in FIGS. 23 and 24, a first cam member 1022 protrudes from or is attached to the distal staple support portion 1010 and has a first camming surface or ramp 1024 formed thereon. The distal connection member 1070 further includes a second distal cam portion 1026 that has a second or distal camming surface or ramp 1028 formed thereon as shown in FIGS. 23 and 24. In at least one arrangement, the camming surfaces 1024 have the same slope or angle as the slope/angle of camming surfaces 984. Likewise, the camming surfaces 1028 have the same slope/angle as the slope/angle of camming surfaces 974. In at least one embodiment, each distal staple driver 1000 a, 1000 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the distal staple drivers 1000 a, 1000 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

FIGS. 25-27 illustrate an exemplary proximal staple driver 1100 a. Proximal staple driver 1100 b may essentially be a mirror image of proximal staple driver 1100 a. Each proximal staple driver 1100 a, 1100 b includes a proximal staple support portion 1110 that is configured to support a corresponding proximal most staple 820 ap thereon. As can be seen in FIGS. 25-27, the proximal staple support portion 1110 comprises a distal support column 1114 and a proximal support column 1118. The proximal staple support portion 1110 further includes a distal support cradle 1116 and a proximal support cradle 1120 for supporting portions of the staple crown 827 a of the corresponding proximal staple 820 ap. When the staple crown 827 a of the proximal staple 820 ap is supported on the support cradles 1116 and 1120, the distal leg 823 a of the staple 820 ap is essentially axially aligned with the distal support column 1116 and the proximal leg 825 a is essentially axially aligned with the proximal support column 1118. In at least one arrangement, the proximal staple drivers 1100 a, 1100 b include a body member 1170. The body member 1170 is configured to slidably engage the corresponding proximal-most driver guide (designated as 860P in FIG. 21).

In at least one arrangement, the body member 1170 includes a hook-shaped distal slot 1172 that is configured to be “hookingly engaged” by the hook-shaped portion 862 of the proximal-most driver guide 860P. In addition, the body member 1170 may include a projection 1174 that is configured to be slidably received within a corresponding slot 869 in the proximal most staple driver guide 860P. Thus, each proximal staple driver 1100 a, 1100 b is slidably engaged with a corresponding driver guide 860P. In addition, in the array 990 a of staple drivers 900 a, 1000 a, 1100 a, the distal support column 1114 of the proximal staple driver 1100 a may be slidably received within a corresponding first staple leg groove 854 in the first cartridge wall portion 852. Likewise, the distal support column 1114 of the proximal staple driver 1110 b may be slidably received within a corresponding primary staple leg groove 874 in the primary cartridge wall portion 872. As can also be seen in FIGS. 26 and 27, a first proximal cam portion 1122 protrudes from or is attached to the body member 1170 and has a first proximal camming surface or ramp 1124 formed thereon. The body member 1170 also includes a second distal cam portion or ramp 1126 that has a second distal camming surface 1128 formed thereon. In at least one arrangement, the camming surfaces 1124 have the same slope or angle as the slopes/angles of the camming surfaces or ramps 984, 1024. Likewise, the camming surfaces 1128 may have the same slope/angle as the slope/angle of camming surface 974 and 1028. In at least one embodiment, each proximal staple driver 1100 a, 1100 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the proximal staple drivers 1100 a, 1100 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 20, it can be seen that in the staple driver array 990 a in the illustrated arrangement, the distal cam portion 1126 of the proximal staple driver 1100 a as well as each of the first cam members 972 of the staple drivers 900 a, as well as the distal cam portion 1026 of the distal staple driver 1000 a are all aligned along a first cam axis FCA. Thus, in at least one embodiment, each of the first distal camming surfaces 1028, 1128 as well as each of the first camming surfaces 974 is axially aligned on the first cam axis FCA. Also, the second proximal cam portion 1122 of the proximal staple driver 1100 a and the proximal cam portion 1022 of the distal staple driver 1000 a, as well as each of the second cam members 982 of the staple drivers 900 a is all axially aligned along a second cam axis SCA. Thus, the proximal camming surfaces 1024, 1124 and the second camming surfaces 984 of the staple drivers 900 a are axially aligned along the second cam axis SCA. Also in the illustrated staple driver array 990 b, the distal cam portion 1126 of the proximal staple driver 1100 b as well as the distal cam portion 1026 of the distal staple driver 1000 b as well as each of the cam members 972 of the staple drivers 900 b are all aligned along a primary cam axis PCA. Thus, in at least one embodiment, the distal camming surfaces 1128, 1028, as well as each of the first camming surfaces 974 in the staple driver array 990 b are axially aligned on the primary cam axis PCA.

Still referring to FIG. 20, the staple driver array 990 b in the illustrated arrangement, the first distal cam portion 1126 of the proximal staple driver 1100 b as well as each of the first cam members 972 of the staple drivers 900 b as well as the first distal cam portion 1026 of the distal staple driver 1000 b are all aligned along a primary cam axis PCA. Thus, in at least one embodiment, each of the first distal camming surfaces 1028, 1128 as well as each of the first camming surfaces 974 in the staple driver array 990 b is axially aligned on the primary cam axis PCA. Also, the second proximal cam portion 1122 of the proximal staple driver 1100 b and second proximal cam portion 1022 of the distal staple driver 1000 b, as well as each of the second cam members 982 of the staple drivers 900 b are all axially aligned along a secondary cam axis SDCA. Thus each of the proximal camming surfaces 1024, 1124 and the second camming surfaces 984 of the staple drivers 900 b are axially aligned along the second cam axis SDCA.

As was discussed above, in the array 990 a, the ramp or camming surface 764 of the sled or camming member 760 is aligned with the second cam axis SCA. Likewise, the ramp or camming surface 762 is aligned with the first cam axis FCA. The ramp or camming surface 766 is aligned on the primary cam axis PCA and the ramp or camming surface 768 is aligned with the secondary cam axis SDCA. Thus, the ramp surface 764 is aligned with a portion of each of the crowns 827 c of staples 820 c. The ramp surface 762 is aligned with a portion of each of the crowns 827 c of staples 820 a as well as the crowns 827 c of the staples 820 cd. Likewise, in the array 990 b of the staple drivers 1000 b, 900 b, 1100 b, the ramp surface 766 is aligned with a portion of the crowns 827 a of each of the staples 820 a as well as a portion of the crown 827 a of the proximal most staple 820 ap. The ramp surface 768 is aligned with a portion of the crown 827 c of each of the staples 820 c as well as a portion of the crown 827 c of the distal most staple 820 cd. Stated another way, none of the ramps 764, 762, 766, 768 are aligned with any of the staple legs of the staples 820 a, 820 b, 820 c, 820 cd and 820 ap. Such arrangement therefore enables the third proximal support columns 958 of each of the staple drivers 900 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. As well as the proximal support column 1018 of the distal staple driver 1000 a to be slidably received within a corresponding support groove or slot 858 in the cartridge wall portion 856. In addition, the first distal support columns 914 of each of the staple drivers 900 a are slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. In addition, the distal support column 1114 of the proximal staple driver 1100 a is slidably received within a support groove or slot 854. In the staple driver array 990 a, each of the support columns 1014, 918, 934, 938, 954, 1118 are also slidably supported in corresponding driver guides 860D, 860, 860P that are formed in the cartridge body 802 and may have the same heights or similar heights as the heights of the wall portions 852, 856.

When the surgical instrument is “fired” or stated another way, when the firing drive system 80 is actuated to drive the firing beam 280 distally, the tissue cutting member 750 contacts the sled or camming member 760 and drives the camming member 760 distally through the staple cartridge 800. As can be seen in FIG. 20, the camming members 982 of the staple driver 900 a are located “inboard” from the support columns 958 (and the staple legs 825 c supported thereon). Likewise, the camming member 1022 of the distal staple driver 1000 a is located inboard of the proximal support column 1018 (and the staple leg 825 c of the distal most staple 820 cd supported thereon). In addition, the camming members 972 are all located inboard of the proximal support columns 914 (and the staple legs 823 a of the staples 820 a supported thereon). Also, the camming member 1126 of the proximal staple driver 1100 a is located inboard of the support column 1114 (and the staple leg 823 a of the proximal most staple 820 ap supported thereon). The drivers 1000 b, 900 b, 1100 b in driver array 990 b are similarly configured. Such arrangements permit the support columns to either be slidably supported in corresponding slots in the cartridge wall portions or in slots in corresponding driver guides formed within the cartridge body through their entire range of upward travel.

As can be appreciated from reference to FIG. 20, when the staple drivers 900 a, 1000 a and 1100 a are all operably supported in the staple cartridge in the staple driver array 990 a, the staple drivers 900 a, 1000 a, 1100 a form a first longitudinal row 1210 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1210 a extend in a first direction as was described above. Likewise, the staple drivers 900 a form a second longitudinal row 1212 a of staples 820 b that are adjacent the first longitudinal row 1210 a. The staples 820 b in the second longitudinal row 1212 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1210 a. In addition, the staple drivers 900 a form a third longitudinal row 1214 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 1214 a is adjacent to the second longitudinal row 1212 a.

Still referring to FIG. 20, when the staple drivers 900 b are all operably supported in the staple cartridge in the staple driver array 990 b, the staple drivers 900 b form a first longitudinal row 1210 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1201 b extend in a first direction as was described above. Likewise, the staple drivers 900 b form a second longitudinal row 1212 b of staples 820 b that are adjacent the first longitudinal row 1210 b. The staples 820 b in the second longitudinal row 1210 b extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1210 b. In addition, the staple drivers 900 b form a third longitudinal row 1214 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. Stated another way, the staple crown of the staples 820 a may lie along an axis and the staples 820 c may lie along another axis that is parallel to the axis along which the staple crowns of the staples 820 a lie as will be discussed in further detail below. The third longitudinal row 1214 b is adjacent to the second longitudinal row 1212 b.

Thus, when employing the staple driver arrays 990 a, 990 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the distal driver 1000 a supports a distal most staple 820 cd in the longitudinal row of staples 1214 a that is extending in the same direction and essentially beside the distal most staple 820 a in the longitudinal row 1210 a. Similarly, the proximal driver 1100 a supports a proximal most staple 820 ap in the longitudinal row 1210 a of staples that extends in the same direction and is essentially beside the proximal most staple 820 c in the longitudinal row 1214 a. Likewise, distal driver 1000 b supports a distal most staple 820 cd in the longitudinal row of staples 1214 b that is extending in the same direction and essentially beside the distal most staple 820 a in the longitudinal row 1210 b. Similarly, the proximal driver 1100 b supports a proximal most staple 820 ap in the longitudinal row 1210 b of staples that extends in the same direction and is essentially beside the proximal most staple 820 c in the longitudinal row 1214 b. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples. As used in this context, the term “line of staples” collectively refers to the longitudinal rows of staples on one side of the elongate slot 804 in the staple cartridge body 802. For example, line of staples, generally designated as 1220 a, collectively refers to the longitudinal rows 1200 a, 1202 a, 1204 a. Line of staples 1220 b collectively refers to the longitudinal rows 1200 b, 1202 b, 1204 b.

Other staple driver arrays 1300 a, 1300 b are illustrated in FIGS. 28 and 29. As can be seen in those Figures, the staple driver array 1300 a employs a distal staple driver 1000 a and a plurality of staple drivers 900 a in the manners described above. This array also employs a proximal staple driver 1310 a that operably supports a total of four staples. FIGS. 30-32 illustrate one exemplary form of a proximal staple driver 1310 a with it being understood that, in at least one arrangement, the proximal staple driver 1310 b essentially contains the same features as a proximal staple driver 1310 a and may be a mirror image thereof. Each proximal staple driver 1310 a, 1310 b comprises a driver body 1311. In at least one form, the driver body 1311 includes a first or innermost staple support portion 1320 that is configured to support a staple 820 a thereon, a second or central staple support portion 1350 that is configured to support a staple 820 b thereon, third support portion 1370 that is configured to support a staple 820 c thereon and a fourth or proximal most staple support portion 1390 that is configured to support a proximal most staple 820 cp thereon.

As can be seen in FIGS. 30 and 31, the first staple support portion 1320 comprises a first distal support column 1324 and a first proximal support column 1328. The first staple support portion 1320 further includes a first distal support cradle 1326 and a first proximal support cradle 1330 for supporting portions of the first staple crown 827 a. As can be seen in FIG. 31, when the first staple crown 827 a of the first staple 820 a is supported on the support cradles 1326 and 1330, the first distal leg 823 a is essentially axially aligned with the first distal support column 1324 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 1328. In addition, the staple crown 827 a is supported or oriented along a first base axis FBA.

Still referring to FIGS. 30 and 31, the proximal staple driver 1310 a further comprises second staple support portion 1350 that comprises a second distal support column 1354 and a second proximal support column 1358. The second staple support portion 1350 further includes a second distal support cradle 1356 and a second proximal support cradle 1360 for supporting portions of the second staple crown 827 b therein. As can be seen in FIG. 31, when the second staple crown 827 b of the second staple 820 b is supported in the cradles 1356, 1360, the second distal leg 823 b is essentially axially aligned with the second distal support column 1354 and the second proximal leg 825 b is essentially axially aligned with the second proximal support column 1358. In addition, the staple crown 827 b is supported or oriented along a second base axis SBA that, in at least one arrangement, is transverse to the first base axis FBA.

As can also be seen in FIGS. 30 and 31, the proximal staple driver 1310 a comprises a third staple support portion 1370 that includes a third distal support column 1374 and a third proximal support column 1378. The third staple support portion 1370 further includes a third distal support cradle 1376 and a third proximal support cradle 1380 configured to support portions of the third staple crown 827 c of the third staple 820 c therein. As can be seen in FIG. 31, when the third crown 827 c of the third staple 820 c is supported in the cradles 1376, 1380, the third distal leg 823 c is essentially axially aligned with the third distal support column 1374 and the third proximal leg 825 c is essentially axially aligned with the third proximal support column 1378. In addition, the staple crown 827 c is supported or oriented along a third base axis TBA that is, in at least one arrangement, parallel with the first base axis FBA and transverse to the second base axis SBA.

Still referring to FIGS. 30 and 31, the proximal staple driver 1310 a comprises a fourth staple support portion 1390 that includes a fourth distal support column 1394 and a fourth proximal support column 1398. The fourth staple support portion 1390 further includes a fourth distal support cradle 1396 and a third proximal support cradle 1400 configured to support portions of the fourth staple crown 827 cp of the proximal most or fourth staple 820 cp therein. As can be seen in FIG. 31, when the fourth crown 827 cp of the fourth staple 820 cp is supported in the cradles 1396, 1400, the fourth distal leg 823 cp is essentially axially aligned with the fourth distal support column 1394 and the fourth proximal leg 825 cp is essentially axially aligned with the fourth proximal support column 1398. In addition, the staple crown 827 cp is supported or oriented along a proximal base axis PBA that is, in at least one arrangement, parallel with the first base axis and the third base axis TBA and transverse to the second base axis SBA.

In at least one arrangement, the first staple support portion 1320, the second staple support portion 1350, the third staple support portion 1370 and the fourth staple support portion 1390 are all coupled together by a connector portion 1410. In at least one arrangement, the connector portion 1410 is formed with a centrally disposed opening or aperture 1412 that is configured to slidably receive the proximal most driver guide 860P therein. See FIG. 29. The connector portion 1410 is formed with a first hook-shaped slot 1414 that is adapted to be hookingly engaged by a hooked shaped portion 862P and a second hook shaped slot 1416 that is adapted to be hookingly engaged by a hook shaped portion 864P on the proximal most driver guide 860P that is formed in the cartridge body. In addition, a third slot 1418 is formed in the connector portion 1410 for slidably engaging a correspondingly shaped portion 866P of the driver guide 860P. A fourth slot 1420 is formed in the connector portion 1410 for slidably engaging a hook shaped portion 862 of the adjacent driver guide 860. See FIG. 29. Also in the illustrated embodiment, the connector portion 1410 includes a fifth slot 1422 for slidably receiving a correspondingly shaped portion 868P of the proximal most driver guide 860P. In addition, in the array 1300 a of staple drivers 900 a, 1000 a, 1310 a, the support columns 1324, 1394 of the proximal staple driver 1310 a may be slidably received within a corresponding first support groove or slot 854 in the first cartridge wall portion 852 in the manner described above. In addition, the support column 1378 may be slidably supported in a corresponding support groove or slot 858 in the second cartridge wall portion 856. Likewise, the support columns 1324, 1394 of the proximal staple driver 1310 b may be slidably received within a corresponding primary support groove or slot 874 in the primary cartridge wall portion 872 in the manner described above. In addition, the support column 1378 of the proximal staple driver 1310 b may be slidably supported in a corresponding support groove or slot 878 in the secondary cartridge wall portion 876.

As can also be seen in FIGS. 31 and 32, the connector portion 1410 includes a first cam portion 1430 that has a first camming surface or ramp 1432 formed thereon. The connector portion 1410 also includes a second cam portion 1434 that has a second a second camming surface 1436 formed thereon. In at least one arrangement, the camming surfaces 1432, 1436 have the same slope or angle which may be the same or different from the slope(s) and/or angles(s) of the camming surfaces or ramps 974, 984. In at least one embodiment, each proximal staple driver 1310 a, 1310 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the proximal staple drivers 1310 a, 1310 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 28, it can be seen that in the staple driver array 1300 a in the illustrated arrangement, the first cam portion 1430 of the proximal staple driver 1310 a and the distal cam portion 1026 of the distal staple driver 1000 a, as well as each of the first cam members 972 of the staple drivers 900 a are all axially aligned along a first cam axis FCA. Thus the proximal camming surface 1028, the second camming surfaces 974 of the staple drivers 900 a and the camming surface 1432 are all axially aligned along the first cam axis FCA. The second cam portion 1434 of the proximal staple driver 1310 a, as well as each of the second cam members 982 of the staple drivers 900 a, as well as the cam member 1022 of the distal staple driver 1000 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 1436, as well as each of the camming surfaces 984 and camming surface 1024 are all axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 1300 b, the cam portion 1430 of the proximal staple driver 1310 b, as well as each of the cam members 972 of the staple drivers 900 b, as well as the cam portion 1026 of the distal staple driver 1000 b are all aligned along a primary cam axis PCA. Thus, the second camming surface 1432 of the proximal staple driver 1310 b, the second camming surfaces 974 of the staple drivers 900 b and the camming surface 1028 of the distal staple driver 1000 b are all axially aligned along the second primary cam axis PCA. Still referring to FIG. 28, in the staple driver array 1300 b of the illustrated arrangement, the second cam portion 1434 of the proximal staple driver 1310 b, as well as each of the cam members 982 of the staple drivers 900 b as well as the first proximal cam portion 1022 of the distal staple driver 1000 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, each of the camming surfaces 1436 as well as each of the camming surfaces 984 and camming surface 1024 are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 28, when the staple drivers 900 a, 1000 a and 1310 a are all operably supported in the staple cartridge in the staple driver array 1300 a, the staple drivers 900 a, 1000 a, 1310 a form a first longitudinal row 1450 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1450 a extend in a first direction as was described above. Likewise, the staple drivers 900 a and the proximal staple driver 1310 a form a second longitudinal row 1460 a of staples 820 b that are adjacent the first longitudinal row 1450 a. The staples 820 b in the second longitudinal row 1460 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1450 a. In addition, the staple drivers 1000 a, 900 a and 1310 a form a third longitudinal row 1470 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 1470 a is adjacent to the second longitudinal row 1460 a.

Still referring to FIG. 28, when the staple drivers 1000 b, 900 b and 1310 b are all operably supported in the staple cartridge in the staple driver array 1300 b, the staple drivers 1000 b, 900 b and 1310 b form a primary longitudinal row 1450 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the primary longitudinal row 1450 b extend in a first direction as was described above. Likewise, the staple drivers 900 b and 1310 b form a secondary longitudinal row 1460 b of staples 820 b that are adjacent the primary longitudinal row 1450 b. The staples 820 b in the secondary longitudinal row 1460 b extend in a second direction that is different from the first direction of the staples 820 a in the primary longitudinal row 1450 b. In addition, the staple drivers 1000 b, 900 b and 1310 b form a tertiary longitudinal row 1470 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 1470 b is adjacent to the secondary longitudinal row 1460 b.

Thus, when employing the staple driver arrays 1300 a, 1300 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the distal driver 1000 a supports a distal most staple 820 cd in the longitudinal row of staples 1470 a that is extending in the same direction and essentially beside the distal most staple in the longitudinal row 1450 a. Similarly, the proximal driver 1310 a supports two proximal most staples 820 c and 820 cp in the longitudinal rows 1450 a and 1470 a, respectively, of staples that extend in the same direction as the proximal most staple in the longitudinal row 1470 a. Likewise, distal driver 1000 b supports a distal most staple 820 cd in the longitudinal row of staples 1470 b that is extending in the same direction and essentially beside the distal most staple in the longitudinal row 1450 b. Similarly, the proximal driver 1310 b supports a proximal most staple in the longitudinal row 1450 b of staples that extends in the same direction and is essentially beside the proximal most staple in the longitudinal row 1470 b. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples. As used in this context, the term “line of staples” collectively refers to the longitudinal rows of staples on one side of the elongate slot 804 in the staple cartridge body 802. For example, line of staples, generally designated as 1480 a, collectively refers to the longitudinal rows 1450 a, 1460 a, 1470 a of staples. Line of staples 1480 b collectively refers to the longitudinal rows 1450 b, 1460 b, 1470 b of staples.

As was discussed above, in the array 1300 a, the ramp or camming member 764 of the sled or camming actuator 760 is aligned with the second cam axis SCA. Likewise, the ramp or camming member 762 is aligned with the first cam axis FCA. The ramp or camming member 766 is aligned on the primary cam axis PCA and the ramp or camming member 768 is aligned with the secondary cam axis SDCA. Thus, the ramp or camming member 764 is aligned with a portion of each of the crowns 827 c of staples 820 c and 820 cd. The ramp or camming member 762 is aligned with a portion of each of the crowns 827 a of staples 820 a as well as the crown 827 c of the proximal most staple 820 cp. Likewise, in the array 1300 b of the staple drivers 1000 b, 900 b, 1310 b, the ramp or camming member 766 is aligned with a portion of the crowns 827 a of each of the staples 820 a as well as a portion of the crown 827 c of the proximal most staple 820 cp. The ramp or camming member 768 is aligned with a portion of the crown 827 c of each of the staples 820 c as well as a portion of the crown 827 c of the distal most staple 820 cd. Stated another way, none of the ramps or camming members 764, 762, 766, 768 are aligned with any of the staple legs of the staples 820 a, 820 b, 820 c, 820 cd and 820 cp. Such arrangement therefore enables the third proximal support columns 958 of each of the staple drivers 900 a, as well as the proximal support column 1018 of the distal staple driver 1000 a, as well as the support column 1378 of the proximal staple driver 1310 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. Likewise, the first distal support columns 914 of each of the staple drivers 900 a, as well as the support columns 1324, 1394 of the proximal staple driver 1310 a are all slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. In the staple driver array 1300 a, each of the support columns 1014, 918, 934, 938, 954, 1328, 1354, 1358, 1374, 1398 are also slidably supported in corresponding driver guides 860D, 860, 860P that are formed in the cartridge body 802 and may have the same heights or similar heights as the heights of the wall portions 852, 856.

Other staple driver arrays 1500 a, 1500 b are illustrated in FIGS. 33 and 34. As can be seen in those Figures, the staple driver array 1500 a employs a plurality of staple drivers 1510 a that operably supports three staples. The staple driver array 1500 a also includes a distal staple driver 1610 a that operably supports two staples. Likewise, staple driver array 1500 b includes a plurality of staple drivers 1510 b and a distal staple driver 1610 b. Staple drivers 1510 b may be mirror images of staple drivers 1510 a and include the same features. Distal staple drivers 1610 b may be mirror images of staple drivers 1610 a and include the same features.

FIGS. 35-37 illustrate one exemplary form of a staple driver 1510 a with it being understood that, in at least one arrangement, a staple driver 1510 b essentially contains the same features as a staple driver 1510 a and may be a mirror image thereof. Each staple driver 1510 a, 1510 b comprises a staple driver body 1511. In the illustrated arrangement, the driver body 1511 includes a first or innermost staple support portion 1520 that is configured to support a staple 820 a thereon, a second or central staple support portion 1550 that is configured to support a staple 820 b thereon and a third support portion 1570 that is configured to support a staple 820 c thereon. As can be seen in FIG. 35, the first staple support portion 1520 comprises a first distal support column 1524 and a first proximal support column 1528. The first staple support portion 1520 further includes a first distal support cradle 1526 and a first proximal support cradle 1530 for supporting portions of the staple crown 827 a of a staple 820 a. As can be seen in FIG. 31, when the staple crown 827 a of the staple 820 a is supported on the support cradles 1526 and 1530, the distal leg 823 a is essentially axially aligned with the first distal support column 1524 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 1528. When the staple 820 a is supported on the first staple support portion 1520, the staple crown 827 a is aligned on a first base axis FBA.

Still referring to FIGS. 35 and 36, the proximal staple driver 1510 a further comprises second staple support portion 1550 that comprises a second distal support column 1554 and a second proximal support column 1558. The second staple support portion 1550 further includes a second distal support cradle 1556 and a second proximal support cradle 1560 for supporting portions of a staple crown 827 b of a staple 820 b therein. As can be seen in FIG. 36, when the staple crown 827 b of the staple 820 b is supported in the cradles 1556, 1560, the distal leg 823 b is essentially axially aligned with the second distal support column 1554 and the proximal leg 825 b is essentially axially aligned with the second proximal support column 1558. When the staple 820 b is supported on the second staple support portion 1550, the staple crown 827 b is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is transverse to the first base axis FBA.

As can also be seen in FIGS. 35 and 36, the proximal staple driver 1510 a comprises a third staple support portion 1570 that includes a third distal support column 1574 and a third proximal support column 1578. The third staple support portion 1570 further includes a third distal support cradle 1576 and a third proximal support cradle 1580 configured to support portions of a staple crown 827 c of a third staple 820 c therein. As can be seen in FIG. 31, when the crown 827 c of the staple 820 c is supported in the cradles 1576, 1580, the distal leg 823 c is essentially axially aligned with the distal support column 1574 and the proximal leg 825 c is essentially axially aligned with the third proximal support column 1578. When the staple 820 c is supported on the third staple support portion 1570, the staple crown 827 c is aligned on a third base axis TBA. In the illustrated arrangement, the third base axis TBA is parallel to the first base axis FBA and transverse to the second base axis SBA.

Still referring to FIGS. 35-37, in at least one arrangement, the first staple support portion 1520, the second staple support portion 1550 and the third staple support portion 1570 are all coupled together by a connector portion 1590. In at least one arrangement, the connector portion 1590 is formed with a centrally disposed opening or aperture 1592 that is configured to slidably receive a corresponding first driver guide 1700 therein. See FIG. 34. The connector portion 1590 is formed with a first hook-shaped slot 1594 that is adapted to be hookingly engage by a hooked shaped portion 1702 on the first driver guide 1700. The hook shaped portion 1702 is adapted to slidably support the support column 1574 therein. In addition, as can be further seen in FIG. 34, each first driver guide 1700 includes a slot 1704 that is configured to slidably receive the second proximal support column 1558 of the corresponding staple driver 1510 a therein. Each staple driver 1510 a is also configured to slidably engage a second driver guide 1720 as shown in FIG. 34. Each second driver guide 1720 includes a first slot 1722 that is configured to slidably receive therein a first proximal support column 1528 of a corresponding staple driver 1510 a. In addition, each second driver guide 1720 further has a second slot 1724 that is configured to slidably receive therein a second distal support column 1554 of the corresponding staple driver 1510 a therein.

As can also be seen in FIGS. 35 and 36, the connector portion 1590 includes a first cam portion 1596 that has a first camming surface or ramp 1598 formed thereon. The connector portion 1590 also includes a second cam portion 1600 that has a second a second camming surface 1602 formed thereon. In at least one arrangement, the camming surfaces 1598, 1602 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each staple driver 1510 a, 1510 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the proximal staple drivers 1510 a, 1510 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

The staple driver array 1500 a in the illustrated embodiment also comprises a distal staple driver 1610 a that is configured to operably support two staples. FIGS. 38-40 illustrate one exemplary form of a distal staple driver 1610 a with it being understood that, in at least one arrangement, a staple driver 1610 b essentially contains the same features as a staple driver 1610 a and may be a mirror image thereof. Each staple driver 1610 a, 1610 b includes a driver body 1611. In the illustrated arrangement, each driver body 1611 includes a first staple support portion 1620 that is configured to support a staple 820 a thereon and a second staple support portion 1650 that is configured to support a staple 820 c thereon. As can be seen in FIG. 30, the first staple support portion 1620 comprises a first distal support column 1624 and a first proximal support column 1628. The first staple support portion 1620 further includes a first distal support cradle 1626 and a first proximal support cradle 1630 for supporting portions of the first staple crown 827 a. As can be seen in FIG. 39, when the staple crown 827 a of the staple 820 a is supported on the support cradles 1626 and 1630, the distal leg 823 a is essentially axially aligned with the first distal support column 1624 and the proximal leg 825 a is essentially axially aligned with the first proximal support column 1628. When the staple 820 a is supported on the first staple support portion 1620, the staple crown 827 a is aligned on a first base axis FBA.

Still referring to FIGS. 38 and 39, the distal staple driver 1610 a further comprises second staple support portion 1650 that comprises a second distal support column 1654 and a second proximal support column 1658. The second staple support portion 1650 further includes a second distal support cradle 1656 and a second proximal support cradle 1660 for supporting portions of the staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 39, when the staple crown 827 c of the staple 820 c is supported in the cradles 1656, 1660, the distal leg 823 c is essentially axially aligned with the second distal support column 1654 and the proximal leg 825 c is essentially axially aligned with the second proximal support column 1658. When the staple 820 c is supported on the second staple support portion 1650, the staple crown 827 c is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is parallel to the first base axis FBA.

In at least one arrangement, the first staple support portion 1620 and the second staple support portion 1650 of the distal staple driver 1610 a are coupled together by a connector portion 1690. In at least one arrangement, the driver body portion 1690 is formed with a centrally disposed opening or aperture 1692 that is configured to slidably receive a corresponding distal driver guide 1730 d therein. See FIG. 34. The distal driver guide 1730 d includes a slot 1732 that is configured to slidably receive the first distal support column 1624 of the distal staple driver 1610 a therein. The distal staple driver 1610 a is also configured to slidably engage the distal most second driver guide 1720 d as shown in FIG. 34. The distal most second staple driver guide 1720 d includes a first slot 1722 d that is configured to slidably receive therein the first proximal support column 1628 of the distal staple driver 1610 a. In addition, the distal most second staple driver guide 1720 d further has a second slot 1724 d that is configured to slidably receive therein a second distal support column 1554 of the corresponding staple driver 1510 a therein.

As can also be seen in FIGS. 39 and 40, the connector portion 1690 includes a first cam portion 1694 that has a first camming surface or ramp 1696 formed thereon. The connector portion 1690 also includes a second cam portion 1698 that has a second camming surface 1700 formed thereon. In at least one arrangement, the camming surfaces 1696, 1700 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each distal driver 1610 a, 1610 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the distal drivers 1610 a, 1610 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 33, it can be seen that in the staple driver array 1500 a in the illustrated arrangement, the first cam portion 1596 of each of the staple drivers 1510 a and the cam portion 1694 of the distal staple driver 1610 a are all axially aligned along a first cam axis FCA. Thus the camming surface 1598 of each of the drivers 1510 a and the camming surface 1696 of the distal driver 1610 a are axially aligned along the first cam axis FCA. The second cam portion 1600 of each of the drivers 1510 a and the cam portion 1698 of the distal staple driver 1610 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 1602 of each of the drivers 1510 a and the camming surface 1700 of the distal driver 1610 a are axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 1500 b, the cam portion 1596 of each of the drivers 1510 b and the cam portion 1694 of the distal driver 1610 b are all aligned along a primary cam axis PCA. Thus, the camming surface 1598 of each of the drivers 1510 b and the camming surface 1696 of the distal driver 1610 b are axially aligned along the primary cam axis PCA. Still referring to FIG. 33, in the staple driver array 1500 b of the illustrated arrangement, the cam portion 1600 of each of the drivers 1510 b and the cam portion 1698 of the distal driver 1610 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, the camming surface 1602 of each of the drivers 1510 b and the camming surface 1700 of the distal driver 1610 b are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 33, when the drivers 1510 a and 1610 a are all operably supported in the staple cartridge in the staple driver array 1500 a, the staple drivers 1510 a, 1610 a form a first longitudinal row 1750 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 1750 a extend in a first direction as was described above. Likewise, the drivers 1510 a form a second longitudinal row 1760 a of staples 820 b that are adjacent the first longitudinal row 1750 a. The staples 820 b in the second longitudinal row 1760 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 1750 a. In addition, the drivers 1510 a and 1610 a form a third longitudinal row 1770 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 1770 a is adjacent to the second longitudinal row 1760 a.

Still referring to FIG. 33, when the staple drivers 1510 b and 1610 b are all operably supported in the staple cartridge in the staple driver array 1500 b, the staple drivers 1510 b and 1610 b form a primary longitudinal row 1750 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the primary longitudinal row 1750 b extend in a first direction as was described above. Likewise, the staple drivers 1510 b form a secondary longitudinal row 1760 b of staples 820 b that are adjacent the primary longitudinal row 1750 b. The staples 820 b in the secondary longitudinal row 1760 b extend in a second direction that is different from the first direction of the staples 820 a in the primary longitudinal row 1750 b. In addition, the staple drivers 1510 b and 1610 b form a tertiary longitudinal row 1770 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 1770 b is adjacent to the secondary longitudinal row 1760 b.

Thus, when employing the staple driver arrays 1500 a, 1500 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the distal driver 1610 a supports two distal most staples in the longitudinal rows 1750 a, 1770 a that each extend in the same direction. Similarly, the proximal most driver 1510 a supports two proximal most staples in the longitudinal rows 1550 a and 1570 a of staples that extend in the same direction. Likewise, distal driver 1610 b supports two distal most staples in the longitudinal rows 1750 b, 1770 b of staples that extend in the same direction. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples. As used in this context, the term “line of staples” collectively refers to the longitudinal rows of staples on one side of the elongate slot 804 in the staple cartridge body 802. For example, line of staples, generally designated as 1780 a, collectively refers to the longitudinal rows 1750 a, 1760 a, 1770 a of staples. Line of staples 1780 b collectively refers to the longitudinal rows 1750 b, 1760 b, 1770 b of staples.

As was discussed above, in the array 1500 a, the ramp or camming surface 764 of the sled or camming actuator 760 is aligned with the second cam axis SCA. Likewise, the ramp or camming member 762 is aligned with the first cam axis FCA. The ramp or camming member 766 is aligned on the primary cam axis PCA and the ramp or camming member 768 is aligned with the secondary cam axis SDCA. Thus, the ramp or camming member 764 is aligned with a portion of each of the crowns 827 c of staples 820 c. The ramp or camming member 762 is aligned with a portion of each of the crowns 827 a of staples 820 a. Likewise, in the array 1500 b of the staple drivers 1510 b, 1610 b, the ramp or camming member 766 is aligned with a portion of the crowns 827 a of each of the staples 820 a. The ramp or camming member 768 is aligned with a portion of the crown 827 c of each of the staples 820 c. Stated another way, none of the ramps or camming members 764, 762, 766, 768 are aligned with any of the staple legs of the staples 820 a, 820 c. Such arrangement therefore enables the third proximal support columns 1578 of each of the staple drivers 1510 a, as well as the proximal support column 1658 of the distal staple driver 1610 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. Likewise, the first distal support columns 1524 of each of the staple drivers 1510 a, as well as the support column 1624 of the distal staple driver 1610 a are all slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. In the staple driver array 1500 a, each of the support columns 1654, 1628, 1554, 1558, 1574, 1528 are also slidably supported in corresponding driver guides 1700, 1720, 1730 d that are formed in the cartridge body 802 and may have the same heights or similar heights as the heights of the cartridge wall portions 852, 856.

Other staple driver arrays 1800 a, 1800 b are illustrated in FIGS. 41 and 42. As can be seen in those Figures, the staple driver array 1800 a employs a plurality of staple drivers 1810 a that operably supports three staples. The staple driver array 1800 a also includes a proximal staple driver 1910 a that operably supports two staples. Likewise, staple driver array 1800 b includes a plurality of staple drivers 1810 b and a proximal staple driver 1910 b. Staple drivers 1810 b may be mirror images of staple drivers 1810 a and include the same features. Proximal staple drivers 1910 b may be mirror images of staple drivers 1910 a and include the same features.

FIGS. 43-45 illustrate one exemplary form of a staple driver 1810 a with it being understood that, in at least one arrangement, a staple driver 1810 b essentially contains the same features as a staple driver 1810 a and may be a mirror image thereof. Each staple driver 1810 a, 1810 b comprises a staple driver body 1811. In the illustrated arrangement, the driver body 1811 includes a first or innermost staple support portion 1820 that is configured to support a staple 820 a thereon, a second or central staple support portion 1850 that is configured to support a staple 820 b thereon and a third support portion 1870 that is configured to support a staple 820 c thereon. As can be seen in FIG. 43, the first staple support portion 1820 comprises a first distal support column 1824 and a first proximal support column 1828. The first staple support portion 1820 further includes a first distal support cradle 1826 and a first proximal support cradle 1830 for supporting portions of the staple crown 827 a of a staple 820 a. As can be seen in FIG. 44, when the staple crown 827 a of the staple 820 a is supported on the support cradles 1826 and 1830, the distal leg 823 a is essentially axially aligned with the first distal support column 1824 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 1828. When the staple 820 a is supported on the first staple support portion 1820, the staple crown 827 a is aligned on a first base axis FBA.

Still referring to FIGS. 43 and 44, the staple driver 1810 a further comprises second staple support portion 1850 that comprises a second distal support column 1854 and a second proximal support column 1858. The second staple support portion 1850 further includes a second distal support cradle 1856 and a second proximal support cradle 1860 for supporting portions of a staple crown 827 b of a staple 820 b therein. As can be seen in FIG. 44, when the staple crown 827 b of the staple 820 b is supported in the cradles 1856, 1860, the distal leg 823 b is essentially axially aligned with the second distal support column 1854 and the proximal leg 825 b is essentially axially aligned with the second proximal support column 1858. When the staple 820 b is supported on the second staple support portion 1850, the staple crown 827 b is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is transverse to the first base axis FBA. See FIG. 43.

As can also be seen in FIGS. 43 and 44, the staple driver 1810 a comprises a third staple support portion 1870 that includes a third distal support column 1874 and a third proximal support column 1878. The third staple support portion 1870 further includes a third distal support cradle 1876 and a third proximal support cradle 1880 configured to support portions of a staple crown 827 c of a third staple 820 c therein. As can be seen in FIG. 44, when the crown 827 c of the staple 820 c is supported in the cradles 1876, 1880, the distal leg 823 c is essentially axially aligned with the distal support column 1874 and the proximal leg 825 c is essentially axially aligned with the third proximal support column 1878. When the staple 820 c is supported on the third staple support portion 1870, the staple crown 827 c is aligned on a third base axis TBA. In the illustrated arrangement, the third base axis TBA is parallel to the first base axis FBA and transverse to the second base axis SBA. See FIG. 43.

Still referring to FIGS. 43-45, in at least one arrangement, the first staple support portion 1820, the second staple support portion 1850 and the third staple support portion 1870 are all coupled together by a connector portion 1890. In at least one arrangement, the connector portion 1890 is formed with a centrally disposed opening or aperture 1892 that is configured to slidably receive a corresponding first driver guide 2000 therein. See FIG. 42. The connector portion 1890 is formed with a first hook-shaped slot 1894 that is adapted to be hookingly engaged by a hooked shaped portion 2002 on the first driver guide 2000. The hook shaped portion 2002 is adapted to slidably support the support column 1828 therein. In addition, as can be further seen in FIG. 42, each first driver guide 2000 includes a slot 2004 that is configured to slidably receive the support column 1878 of the corresponding staple driver 1810 a therein. Each staple driver 1810 a is also configured to slidably engage a second driver guide 2020 as shown in FIG. 42. Each second driver guide 2020 includes a first slot 2022 that is configured to slidably receive therein a support column 1858 of a corresponding staple driver 1810 a. In addition, each second driver guide 2020 further has a second slot 2024 that is configured to slidably receive therein a support column 1874 of the corresponding staple driver 1810 a therein.

As can also be seen in FIGS. 44 and 45, the connector portion 1890 includes a first cam portion 1896 that has a first camming surface or ramp 1898 formed thereon. The connector portion 1890 also includes a second cam portion 1900 that has a second a second camming surface 1902 formed thereon. In at least one arrangement, the camming surfaces 1898, 1902 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each staple driver 1810 a, 1810 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the proximal staple drivers 1810 a, 1810 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

The staple driver array 1800 a in the illustrated embodiment also comprises a proximal staple driver 1910 a that is configured to operably support two staples. FIGS. 46-48 illustrate one exemplary form of a distal staple driver 1910 a with it being understood that, in at least one arrangement, a staple driver 1910 b essentially contains the same features as a staple driver 1910 a and may be a mirror image thereof. Each staple driver 1910 a, 1910 b includes a driver body 1911. In the illustrated arrangement, each driver body 1911 includes a first staple support portion 1920 that is configured to support a staple 820 a thereon and a second staple support portion 1950 that is configured to support a staple 820 c thereon. As can be seen in FIG. 46, the first staple support portion 1920 comprises a first distal support column 1924 and a first proximal support column 1928. The first staple support portion 1920 further includes a first distal support cradle 1926 and a first proximal support cradle 1930 for supporting portions of the first staple crown 827 a. As can be seen in FIG. 47, when the staple crown 827 a of the staple 820 a is supported on the support cradles 1926 and 1930, the distal leg 823 a is essentially axially aligned with the first distal support column 1924 and the proximal leg 825 a is essentially axially aligned with the first proximal support column 1928. When the staple 820 a is supported on the first staple support portion 1920, the staple crown 827 a is aligned on a first base axis FBA. See FIG. 47.

Still referring to FIGS. 46 and 47, the distal staple driver 1910 a further comprises second staple support portion 1950 that comprises a second distal support column 1954 and a second proximal support column 1958. The second staple support portion 1950 further includes a second distal support cradle 1956 and a second proximal support cradle 1960 for supporting portions of the staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 47, when the staple crown 827 c of the staple 820 c is supported in the cradles 1956, 1960, the distal leg 823 c is essentially axially aligned with the second distal support column 1954 and the proximal leg 825 c is essentially axially aligned with the second proximal support column 1958. When the staple 820 c is supported on the second staple support portion 1950, the staple crown 827 c is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is parallel to the first base axis FBA.

Still referring to FIGS. 46-48, in at least one arrangement, the first staple support portion 1920 and the second staple support portion 1950 of the proximal staple driver 1910 a are coupled together by a connector portion 1990. In at least one arrangement, the connector portion 1990 is formed to slidably mate with a proximal most second driver guide 2020P. See FIG. 42. The support column 1954 of the proximal driver 1910 a is configured to be slidably supported in the slot 2024 in the proximal most second driver guide 2020P.

As can also be seen in FIGS. 47 and 48, the connector portion 1990 includes a first cam portion 1992 that has a first camming surface or ramp 1994 formed thereon. The connector portion 1990 also includes a second cam portion 1996 that has a second camming surface 1998 formed thereon. In at least one arrangement, the camming surfaces 1994, 1998 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each proximal driver 1910 a, 1910 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the distal drivers 1910 a, 1910 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 41, it can be seen that in the staple driver array 1800 a in the illustrated arrangement, the cam portion 1896 of each of the staple drivers 1810 a and the cam portion 1992 of the proximal staple driver 1910 a are all axially aligned along a first cam axis FCA. Thus the camming surface 1994 of each of the drivers 1910 a and the camming surface 1994 of the proximal driver 1910 a are axially aligned along the first cam axis FCA. The second cam portion 1900 of each of the drivers 1910 a and the cam portion 1996 of the proximal staple driver 1910 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 1902 of each of the drivers 1910 a and the camming surface 1998 of the proximal driver 1910 a are axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 1900 b, the cam portion 1896 of each of the drivers 1810 b and the cam portion 1992 of the proximal driver 1910 b are all aligned along a primary cam axis PCA. Thus, the camming surface 1898 of each of the drivers 1810 b and the camming surface 1994 of the proximal driver 1910 b are axially aligned along the primary cam axis PCA. Still referring to FIG. 41, in the staple driver array 1800 b of the illustrated arrangement, the cam portion 1900 of each of the drivers 1810 b and the cam portion 1996 of the proximal driver 1910 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, the camming surface 1902 of each of the drivers 1810 b and the camming surface 1998 of the proximal driver 1910 b are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 41, when the drivers 1810 a and 1910 a are all operably supported in the staple cartridge in the staple driver array 1800 a, the staple drivers 1810 a, 1910 a form a first longitudinal row 2050 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 2050 a extend in a first direction as was described above. Likewise, the drivers 1810 a form a second longitudinal row 2060 a of staples 820 b that are adjacent the first longitudinal row 2050 a. The staples 820 b in the second longitudinal row 2060 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 2050 a. In addition, the drivers 1810 a and 1910 a form a third longitudinal row 2070 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 2070 a is adjacent to the second longitudinal row 2070 a.

Still referring to FIG. 41, when the staple drivers 1810 b and 1910 b are all operably supported in the staple cartridge in the staple driver array 1800 b, the staple drivers 1810 b and 1910 b form a primary longitudinal row 2050 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the primary longitudinal row 2050 b extend in a first direction as was described above. Likewise, the staple drivers 1810 b form a secondary longitudinal row 2060 b of staples 820 b that are adjacent the primary longitudinal row 2050 b. The staples 820 b in the secondary longitudinal row 2060 b extend in a second direction that is different from the first direction of the staples 820 a in the primary longitudinal row 2050 b. In addition, the staple drivers 1810 b and 1910 b form a tertiary longitudinal row 2070 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 2070 b is adjacent to the secondary longitudinal row 2060 b.

Thus, when employing the staple driver arrays 1800 a, 1800 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the proximal driver 1910 a supports two distal most staples in the longitudinal rows 2050 a, 2070 a that each extend in the same direction. Similarly, the distal most driver 1810 a supports two proximal most staples in the longitudinal rows 2050 a and 2070 a of staples that extend in the same direction. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples. As used in this context, the term “line of staples” collectively refers to the longitudinal rows of staples on one side of the elongate slot 804 in the staple cartridge body 802. For example, line of staples, generally designated as 2080 a, collectively refers to the longitudinal rows 2050 a, 2060 a, 2070 a of staples. Line of staples 2080 b collectively refers to the longitudinal rows 2050 b, 2060 b, 2070 b of staples.

As was discussed above, in the array 1800 a, the ramp or camming member 764 of the sled or camming actuator 760 is aligned with the second cam axis SCA. Likewise, the ramp or camming member 762 is aligned with the first cam axis FCA. The ramp or camming member 766 is aligned on the primary cam axis PCA and the ramp or camming member 768 is aligned with the secondary cam axis SDCA. Thus, the ramp or camming member 764 is aligned with a portion of each of the crowns 827 c of staples 820 c. The ramp or camming member 762 is aligned with a portion of each of the crowns 827 a of staples 820 a. Likewise, in the array 1800 b of the staple drivers 1810 b, 1910 b, the ramp or camming member 766 is aligned with a portion of the crowns 827 a of each of the staples 820 a. The ramp or camming member 768 is aligned with a portion of the crown 827 c of each of the staples 820 c. Stated another way, none of the ramps or camming members 764, 762, 766, 768 are aligned with any of the staple legs of the staples 820 a, 820 c. Such arrangement therefore enables the third proximal support columns 1878 of each of the staple drivers 1810 a, as well as the proximal support column 1958 of the proximal staple driver 1910 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. Likewise, the first distal support columns 1824 of each of the staple drivers 1810 a, as well as the support column 1924 of the proximal staple driver 1910 a are all slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. In the staple driver array 1800 a, each of the support columns 1874, 1828, 1854, 1858, 1954, 1928 are also slidably supported in corresponding driver guides 2000, 2020, 2020P that are formed in the cartridge body 802.

Other staple driver arrays 2100 a, 2100 b are illustrated in FIGS. 49 and 50. As can be seen in those Figures, the staple driver array 2100 a employs a plurality of staple drivers 2110 a that operably support five staples and a plurality of drivers 2310 a that operably support four staples. Likewise, staple driver array 2100 b includes a plurality of staple drivers 2310 b and a distal staple driver 2310 b. Staple drivers 2110 b may be mirror images of staple drivers 2110 a and include the same features. Staple drivers 2310 b may be mirror images of staple drivers 2310 a and include the same features.

FIGS. 51-53 illustrate one exemplary form of a staple driver 2110 a with it being understood that, in at least one arrangement, a staple driver 2110 b essentially contains the same features as a staple driver 2110 a and may be a mirror image thereof. Each staple driver 2110 a, 2110 b comprises a staple driver body 2111. In the illustrated arrangement, the driver body 2111 includes a first staple support portion 2120 that is configured to support a staple 820 a thereon. As can be seen in FIG. 51, the first staple support portion 2120 comprises a first distal support column 2124 and a first proximal support column 2128. The first staple support portion 2120 further includes a first distal support cradle 2126 and a first proximal support cradle 2130 for supporting portions of the staple crown 827 a of a corresponding staple 820 a thereon. As can be seen in FIG. 52, when the staple crown 827 a of the staple 820 a is supported on the support cradles 2126 and 2130, the distal leg 823 a is essentially axially aligned with the first distal support column 2124 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 2128. When the staple 820 a is supported on the first staple support portion 2120, the staple crown 827 a is aligned on a first base axis FBA.

Still referring to FIGS. 51 and 52, the staple driver 2110 a further comprises a primary staple support portion 2140 that comprises a second distal support column 2142 and a second proximal support column 2146. The second staple support portion 2140 further includes a second distal support cradle 2144 and a second proximal support cradle 2148 for supporting portions of a staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 52, when the staple crown 827 c of the staple 820 c is supported in the cradles 2144, 2148, the distal leg 823 c is essentially axially aligned with the second distal support column 2142 and the proximal leg 825 c is essentially axially aligned with the second proximal support column 2146. When the staple 820 c is supported on the primary staple support portion 2140, the staple crown 827 c is aligned on a primary base axis PBA. In the illustrated arrangement, the primary base axis PBA is parallel to the first base axis FBA. See FIG. 51.

The staple driver 2110 a further comprises second staple support portion 2150 that comprises a second distal support column 2154 and a second proximal support column 2158. The second staple support portion 2150 further includes a second distal support cradle 2156 and a second proximal support cradle 2160 for supporting portions of a staple crown 827 b of a staple 820 b therein. As can be seen in FIG. 52, when the staple crown 827 b of the staple 820 b is supported in the cradles 2156, 2160, the distal leg 823 b is essentially axially aligned with the second distal support column 2154 and the proximal leg 825 b is essentially axially aligned with the second proximal support column 2158. When the staple 820 b is supported on the second staple support portion 2150, the staple crown 827 b is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is transverse to the first base axis FBA and the primary base axis PBA. See FIG. 51.

As can also be seen in FIGS. 51 and 52, the staple driver 2110 a comprises a third staple support portion 2160 that includes a third distal support column 2162 and a third proximal support column 2166. The third staple support portion 2160 further includes a third distal support cradle 2164 and a third proximal support cradle 2168 configured to support portions of a staple crown 827 a of a staple 820 a therein. As can be seen in FIG. 52, when the crown 827 a of the staple 820 a is supported in the cradles 2164, 2168, the distal leg 823 a is essentially axially aligned with the distal support column 2162 and the proximal leg 825 a is essentially axially aligned with the third proximal support column 2166. When the staple 820 a is supported on the third staple support portion 2160, the staple crown 827 a is aligned on a third base axis TBA. In the illustrated arrangement, the third base axis TBA is parallel to the first base axis FBA and the primary base axis PBA and transverse to the second base axis SBA. See FIG. 51.

As can be further seen in FIGS. 51 and 52, the staple driver 2110 a comprises a fourth staple support portion 2170 that includes a fourth distal support column 2172 and a fourth proximal support column 2176. The fourth staple support portion 2170 further includes a fourth distal support cradle 2174 and a fourth proximal support cradle 2178 configured to support portions of a staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 52, when the crown 827 c of the staple 820 c is supported in the cradles 2174, 2178, the distal leg 823 c is essentially axially aligned with the distal support column 2172 and the proximal leg 825 c is essentially axially aligned with the fourth proximal support column 2176. When the staple 820 c is supported on the fourth staple support portion 2160, the staple crown 827 a is aligned on a fourth base axis FTBA. In the illustrated arrangement, the fourth base axis FTBA is parallel to the first base axis FBA, the primary base axis PBA and the third base axis TBA and is transverse to the second base axis SBA. See FIG. 51.

Still referring to FIGS. 51-53, in at least one arrangement, the first staple support portion 2120, the primary staple support portion 2140, the second staple support portion 2150, the third staple support portion 2160 and the fourth staple support portion 2170 are all coupled together by a connector portion 2190. In at least one arrangement, the connector portion 2190 is formed with a first opening or aperture 2191 that is configured to slidably receive a corresponding first driver guide 2200 therein as will be further discussed below. See FIGS. 50 and 50A. The connector portion 2190 is formed with a first hook-shaped slot 2192 that is adapted to hookingly engage a hooked shaped portion 2202 on the first driver guide 2200. In one instance, the hook shaped portion 2202 has a slot 2204 that is adapted to slidably support a corresponding support column 2172 therein. See FIG. 50A. In another instance, the slot 2204 is configured to receive a corresponding support portion 2144 therein as shown in FIG. 50A. In addition, as can be further seen in FIG. 50A, each first driver guide 2200 includes a slot 2206 that is configured to slidably receive the support column 2156 of the corresponding staple driver 2110 a therein. As can be seen in FIGS. 50A and 51, the connector portion 2190 further has a second opening 2194 therethrough that is configured to slidably engage a second driver guide 2220. Each second driver guide 2220 includes a first hook shaped portion 2222 that has a slot 2224 therein. In one instance, the slot 2224 is configured to slidably receive therein a support column 2128 of a corresponding staple driver 2110 a. In addition, each second driver guide 2220 further has a second slot 2226 that is configured, in one instance, to slidably receive therein a support column 2152 of the corresponding staple driver 2110 a therein.

As can also be seen in FIGS. 52 and 53, the connector portion 2190 includes a first cam portion 2195 that has a first camming surface or ramp 2196 formed thereon. The connector portion 2190 also includes a second cam portion 2197 that has a second a second camming surface 2198 formed thereon. In at least one arrangement, the camming surfaces 2196, 2198 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each staple driver 2110 a, 2110 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the proximal staple drivers 2110 a, 2110 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

The staple driver array 2100 a in the illustrated embodiment also comprises a second staple driver 2310 a that is configured to operably support four staples. FIGS. 54-56 illustrate one exemplary form of a distal staple driver 2310 a with it being understood that, in at least one arrangement, a staple driver 2310 b essentially contains the same features as a staple driver 2310 a and may be a mirror image thereof. Each staple driver 2310 a, 2310 b includes a driver body 2311. In the illustrated arrangement, each driver body 2311 includes a first staple support portion 2320 that is configured to support a staple 820 a thereon, a second staple support portion 2330 that is configured to support a staple 820 b thereon, a third staple support portion 2340 that is configured to operably support another staple 820 b thereon and a fourth staple support portion 2350 that is configured to operably support a staple 820 c thereon. As can be seen in FIG. 54, the first staple support portion 2320 comprises a first distal support column 2322 and a first proximal support column 2326. The first staple support portion 2320 further includes a first distal support cradle 2324 and a first proximal support cradle 2328 for supporting portions of the first staple crown 827 a. As can be seen in FIG. 55, when the staple crown 827 a of the staple 820 a is supported on the support cradles 2324 and 2328, the distal leg 823 a is essentially axially aligned with the first distal support column 2322 and the proximal leg 825 a is essentially axially aligned with the first proximal support column 2326. When the staple 820 a is supported on the first staple support portion 1620, the staple crown 827 a is aligned on a first base axis FBA. See FIG. 54.

Still referring to FIGS. 54 and 55, the second staple driver 2310 a further comprises second staple support portion 2330 that comprises a second distal support column 2332 and a second proximal support column 2326. The second staple support portion 2330 further includes a second distal support cradle 2334 and a second proximal support cradle 2338 for supporting portions of the staple crown 827 b of a staple 820 b therein. As can be seen in FIG. 55, when the staple crown 827 b of the staple 820 b is supported in the cradles 2334, 2338, the distal leg 823 b is essentially axially aligned with the second distal support column 2332 and the proximal leg 825 b is essentially axially aligned with the second proximal support column 2336. When the staple 820 b is supported on the second staple support portion 2330, the staple crown 827 b is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is transverse to the first base axis FBA.

Also in the illustrated embodiment, the second staple driver 2310 a further comprises a third staple support portion 2340 that comprises a third distal support column 2342 and a third proximal support column 2346. The third staple support portion 2340 further includes a third distal support cradle 2344 and a third proximal support cradle 2348 for supporting portions of the staple crown 827 b of another staple 820 b therein. As can be seen in FIG. 55, when the staple crown 827 b of the other staple 820 b is supported in the cradles 2344, 2348, the distal leg 823 b is essentially axially aligned with the third distal support column 2342 and the proximal leg 825 b is essentially axially aligned with the third proximal support column 2346. When the other staple 820 b is supported on the third staple support portion 2340, the staple crown 827 b is aligned on a third base axis TBA. In the illustrated arrangement, the third base axis TBA is parallel with the second base axis SBA and transverse to the first base axis FBA.

Still referring to FIGS. 54 and 55, the second staple driver 2310 a further comprises fourth staple support portion 2350 that comprises a fourth distal support column 2352 and a second proximal support column 2356. The fourth staple support portion 2350 further includes a fourth distal support cradle 2354 and a fourth proximal support cradle 2358 for supporting portions of the staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 55, when the staple crown 827 c of the staple 820 c is supported in the cradles 2354, 2358, the distal leg 823 c is essentially axially aligned with the fourth distal support column 2352 and the proximal leg 825 c is essentially axially aligned with the fourth proximal support column 2356. When the staple 820 c is supported on the fourth staple support portion 2350, the staple crown 827 c is aligned on a fourth base axis FTBA. In the illustrated arrangement, the fourth base axis FTBA is parallel to the first base axis FBA and transverse to the second base axis SBA and the third base axis TBA.

In at least one arrangement, the first staple support portion 2320, the second staple support portion 2330, the third staple support portion 2340 and the fourth staple support portion 2350 of the second staple driver 2310 a are coupled together by a connector portion 2390. In the illustrated example, the connector portion 2390 is formed to slidably mate with a corresponding first staple guide 2200 and a second staple guide 2220. In particular, the connector portion 2390 has a first opening 2391 therein that is configured to slidably receive therein a corresponding first staple guide 2200 therein. When the staple driver 2310 a slidably interfaces with the corresponding first staple guides 2200, the support column 2346 is slidably received in the slot 2206 in the corresponding first driver guide 2200. Likewise, the column 2336 is slidably received in the slot 2206 of another first driver guide 2200. In addition, an inverted first driver guide 22001 interfaces between the first and second drivers 2110 a and 2310 a. As can be seen in FIG. 50, the support column 2166 of the first driver guide 2110 a is slidably received within the slot 2004 in the inverted first driver guide 22001 and the support column 2332 of the corresponding second driver guide 2310 a is slidably received within the slot 2206 of the inverted first driver guide 22001. In addition, the support column 2342 of the second driver guide 2310 a is slidably received within a slot 2226 in a corresponding second driver guide 2220 and the support column 2326 is slidably received within the slot 2224 in the corresponding second driver guide 2220.

As can also be seen in FIGS. 55 and 56, the connector portion 2390 includes a first cam portion 2392 that has a first camming surface or ramp 2394 formed thereon. The connector portion 2390 also includes a second cam portion 2396 that has a second camming surface 2398 formed thereon. In at least one arrangement, the camming surfaces 2394, 2398 have the same slope or angle or they may have different slopes/angles. In at least one embodiment, each second driver 2310 a, 2310 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the second drivers 2310 a, 2310 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 49, it can be seen that in the staple driver array 2100 a in the illustrated arrangement, the cam portion 2195 of each of the first staple drivers 2110 a and the cam portion 2392 of each of the second staple drivers 2310 a are all axially aligned along a first cam axis FCA. Thus, the camming surface 2196 of each of the first drivers 2110 a and the camming surface 2394 of each of the second drivers 2310 a are axially aligned along the first cam axis FCA. As can also be seen in FIG. 49, the second cam portion 2197 of each of the first drivers 2110 a and the cam portion 2396 of each of the second staple drivers 2310 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 2198 of each of the first drivers 2110 a and the camming surface 2398 of each of the second drivers 2310 a are axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 2100 b, the cam portion 2195 of each of the first drivers 2110 b and the cam portion 2392 of each of the second drivers 2310 b are all aligned along a primary cam axis PCA. Thus, the camming surface 2196 of each of the first drivers 2110 b and the camming surface 2394 of the each of the second drivers 2310 b are axially aligned along the primary cam axis PCA. Still referring to FIG. 49, in the staple driver array 2100 b of the illustrated arrangement, the cam portion 2197 of each of the first drivers 2110 b and the cam portion 2396 of each of the second drivers 2310 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, the camming surface 2198 of each of the first drivers 2110 b and the camming surface 2398 of each of the second drivers 2310 b are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 49, when the first drivers 2110 a and the second drivers 2310 a are all operably supported in the staple cartridge in the staple driver array 2100 a, the staple drivers 2110 a, 2310 a form a first longitudinal row 2450 a of staples that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples in the first longitudinal row 2450 a extends in a first direction as was described above. Likewise, the drivers 2110 a and 2310 a form a second longitudinal row 2460 a of staples that are adjacent the first longitudinal row 2450 a. The staples in the second longitudinal row 2460 a extend in a second direction that is different from the first direction of the staples in the first longitudinal row 2450 a. In addition, the drivers 2110 a and 2310 a form a third longitudinal row 2470 a of staples that are oriented in a third direction which may or may not be in the same direction as staples in the first longitudinal row 2450 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 2470 a is adjacent to the second longitudinal row 2060 a.

Still referring to FIG. 49, when the staple drivers 2110 b and 2310 b are all operably supported in the staple cartridge in the staple driver array 2100 b, the staple drivers 2110 b and 2310 b form a primary longitudinal row 2450 b of staples that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples in the primary longitudinal row 2050 b extend in a first direction as was described above. Likewise, the staple drivers 2110 b and 2310 b form a secondary longitudinal row 2460 b of staples that are adjacent the primary longitudinal row 2450 b. The staples in the secondary longitudinal row 2460 b extend in a second direction that is different from the first direction of the staples in the primary longitudinal row 2450 b. In addition, the staple drivers 2110 b and 2310 b form a tertiary longitudinal row 2470 b of staples that are oriented in a third direction which may or may not be in the same direction as staples in the primary longitudinal row 2450 b. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 2470 b is adjacent to the secondary longitudinal row 2460 b.

Thus, when employing the staple driver arrays 2100 a, 2100 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the proximal most first driver 2110 a supports two proximal most staples in the longitudinal rows 2450 a, 2470 a that each extending in the same direction. Similarly, the distal most first driver 2110 a supports two proximal most staples in the longitudinal rows 2450 a and 2470 a of staples that extend in the same direction. The same staple patterns are also established in the staple driver array 2100 b. Such staple patterns may provide a redundant seal arrangement at both ends of each line of staples. As used in this context, the term “line of staples” collectively refers to the longitudinal rows of staples on one side of the elongate slot 804 in the staple cartridge body 802. For example, line of staples, generally designated as 2480 a, collectively refers to the longitudinal rows 2450 a, 2460 a, 2470 a of staples. Line of staples 2480 b collectively refers to the longitudinal rows 2450 b, 2460 b, 2470 b of staples.

As was discussed above, in the array 2100 a, the ramp or camming member 764 of the sled or camming actuator 760 is aligned with the second cam axis SCA. Likewise, the ramp or camming member 762 is aligned with the first cam axis FCA. The ramp or camming member 766 is aligned on the primary cam axis PCA and the ramp or camming member 768 is aligned with the secondary cam axis SDCA. Thus, the ramp or camming member 764 is aligned with a portion of each of the crowns of staples in the longitudinal row 2470 a of staples. The ramp or camming member 762 is aligned with a portion of each of the crowns of the staples in longitudinal row 2450 a. Likewise, in the array 2100 b of the staple drivers 2110 b, 2310 b, the ramp or camming member 766 is aligned with a portion of the crowns of each of the staples in the longitudinal row 2450 b of staples. The ramp or camming member 768 is aligned with a portion of the crown of each of the staples in longitudinal row 2470 b of staples. Stated another way, none of the ramps or camming members 764, 762, 766, 768 are aligned with any of the staple legs of the staples in longitudinal rows 2470 a, 2450 a, 2450 b, 2470 b. Such arrangement therefore enables the support columns 2176 and 2146 of each of the first drivers 2110 a as well as the support column 2356 of each of the second drivers 2310 a to be slidably received within corresponding second support grooves or slots 858 in the second cartridge wall portion 856 of the cartridge body 802. Likewise, the columns 2162 and 2124 of each of the first drivers 2110 a as well as the support column 2322 of each of the second drivers 2310 a are all slidably received within corresponding first support grooves or slots 854 in the first cartridge wall portion 852 of the cartridge 800. The remaining support columns of each of the first and second drivers 2110 a, 2310 a are all slidably received within corresponding driver guides 2200, 2220, 22001. The same arrangement is achieved in the staple driver array 2100 b.

Other staple driver arrays 2500 a, 2500 b are illustrated in FIGS. 57 and 58. As can be seen in those Figures, the staple driver array 2500 a is similar to the staple driver array 2100 a described above, except that the distal most driver in the array is a distal staple driver 2610 a that is adjacent to a second staple driver 2310 a. Whereas, in the staple driver array 2100 a, the first staple driver 2110 a is the distal most driver. The distal staple driver 2610 a operably supports two staples. Likewise, staple driver array 2500 b includes a plurality of first staple drivers 2110 b and a plurality of second staple driver 2310 b as well as a distal staple driver 2610 b. Staple driver 2610 b may be mirror images of staple driver 2610 a and include the same features.

FIGS. 59-61 illustrate one exemplary form of a distal staple driver 2610 a with it being understood that, in at least one arrangement, a distal staple driver 2610 b essentially contains the same features as a distal staple driver 2610 a and may be a mirror image thereof. Each staple driver 2610 a, 2610 b comprises a staple driver body 2611. In the illustrated arrangement, the driver body 2611 includes a first or innermost staple support portion 2620 that is configured to support a staple 820 a thereon and a second or central staple support portion 2650 that is configured to support a staple 820 c thereon. As can be seen in FIG. 59, the first staple support portion 2620 comprises a first distal support column 2622 and a first proximal support column 2626. The first staple support portion 2620 further includes a first distal support cradle 2624 and a first proximal support cradle 2628 for supporting portions of the staple crown 827 a of a staple 820 a. As can be seen in FIG. 60, when the staple crown 827 a of the staple 820 a is supported on the support cradles 2624 and 2628, the distal leg 823 a is essentially axially aligned with the first distal support column 2622 and the first proximal leg 825 a is essentially axially aligned with the first proximal support column 2626. When the staple 820 a is supported on the first staple support portion 2620, the staple crown 827 a is aligned on a first base axis FBA.

Still referring to FIGS. 59 and 60, the distal staple driver 2610 a further comprises second staple support portion 2650 that comprises a second distal support column 2652 and a second proximal support column 2656. The second staple support portion 2650 further includes a second distal support cradle 2654 and a second proximal support cradle 2658 for supporting portions of a staple crown 827 c of a staple 820 c therein. As can be seen in FIG. 60, when the staple crown 827 c of the staple 820 c is supported in the cradles 2654, 2658, the distal leg 823 c is essentially axially aligned with the second distal support column 2652 and the proximal leg 825 c is essentially axially aligned with the second proximal support column 2656. When the staple 820 c is supported on the second staple support portion 2650, the staple crown 827 c is aligned on a second base axis SBA. In the illustrated arrangement, the second base axis SBA is parallel with the first base axis FBA.

In at least one arrangement, the first staple support portion 2620 and the second staple support portion 2650 are coupled together by a connector portion 2690 that is configured to slidably interface with the inverted driver guide 22001. As can be seen in FIG. 58, for example, the support column 2626 of the distal driver 2610 a is slidably received within the slot 2204 in the inverted driver guide 22001. As can also be seen in FIGS. 59-61, the connector portion 2690 includes a first cam portion 2692 that has a first camming surface or ramp 2694 formed thereon. The connector portion 2690 also includes a second cam portion 2696 that has a second a second camming surface 2698 formed thereon. In at least one arrangement, the camming surfaces 2694, 2698 have the same slope or angle or as the corresponding camming surfaces on the first and second drivers 2310 a, 2310 a. In at least one embodiment, each staple driver 2610 a, 2610 b is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the distal staple drivers 2610 a, 2610 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 57, it can be seen that in the staple driver array 2500 a in the illustrated arrangement, the cam portion 2195 of each of the first staple drivers 2110 a and the cam portion 2392 of each of the second drivers 2310 a, as well as the cam portion 2692 of the distal driver 2610 a are all axially aligned along a first cam axis FCA. Thus the camming surface 2196 of each of the first drivers 2110 a and the camming surface 2394 of each of the second drivers 2310 a, as well as the camming surface 2694 of the distal driver 2610 a are axially aligned along the first cam axis FCA. The cam portion 2197 of each of the first drivers 2110 a and the cam portion 2396 of each of the second drivers 2310 a, as well as the cam portion 2696 of the distal driver 2610 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 2198 of each of the first drivers 2110 a and the camming surface 2398 of each of the second drivers 2310 a, as well as the camming surface of the distal driver 2610 a are axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 2500 b, the cam portion 2195 of each of the first drivers 2110 b and the cam portion 2392 of each of the second drivers 2310 b, as well as the cam portion 2692 of the distal driver 2610 b are all aligned along a primary cam axis PCA. Thus, the camming surface 2196 of each of the first drivers 2110 b and the camming surface 2394 of each of the second drivers 2310 b, as well as the camming surface 2694 of the distal driver 2610 b are axially aligned along the primary cam axis PCA. Still referring to FIG. 57, in the staple driver array 2500 b of the illustrated arrangement, the cam portion 2197 of each of the first drivers 2110 b and the cam portion 2396 of each of the second drivers 2310 b as well as the cam portion 2696 of the distal driver 2610 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, the camming surface 2198 of each of the first drivers 2110 b and the camming surface 2398 of each of the second drivers 2310 b as well as the camming surface 2698 of the distal driver 2610 b are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 57, when the drivers 2110 a, 2310 a and 2610 a are all operably supported in the staple cartridge in the staple driver array 2500 a, the staple drivers 2110 a, 2310 a, 2610 a form a first longitudinal row 2750 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 2750 a extend in a first direction as was described above. Likewise, the drivers 2110 a and 2310 a form a second longitudinal row 2760 a of staples 820 b that are adjacent the first longitudinal row 2750 a. The staples 820 b in the second longitudinal row 2760 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 2750 a. In addition, the drivers 2110 a, 2310 a, 2610 a form a third longitudinal row 2770 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 2770 a is adjacent to the second longitudinal row 2760 a.

Still referring to FIG. 57, when the staple drivers 2110 b, 2310 b, 2610 b are all operably supported in the staple cartridge in the staple driver array 2500 b, the staple drivers 2110 b and 2310 b and 2610 b form a primary longitudinal row 2750 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the primary longitudinal row 2750 b extend in a first direction as was described above. Likewise, the staple drivers 2110 b and 2310 b form a secondary longitudinal row 2760 b of staples 820 b that are adjacent the primary longitudinal row 2750 b. The staples 820 b in the secondary longitudinal row 2760 b extend in a second direction that is different from the first direction of the staples 820 a in the primary longitudinal row 1750 b. In addition, the staple drivers 2110 b, 2310 b and 2610 b form a tertiary longitudinal row 2770 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 2770 b is adjacent to the secondary longitudinal row 2760 b.

Thus, when employing the staple driver arrays 2500 a, 2500 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the distal driver 2610 a supports two distal most staples in the longitudinal rows 2750 a, 2770 a that each extending in the same direction. Similarly, the proximal most first driver 2110 a supports two proximal most staples in the longitudinal rows 2750 a and 2770 a of staples that extend in the same direction. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples.

Other staple driver arrays 2800 a, 2800 b are illustrated in FIGS. 62 and 63. As can be seen in those Figures, the staple driver array 2800 a employs a plurality of staple drivers 2610 a that were described above. A staple driver 2610 a comprises a proximal most driver and another staple driver 2610 a forms a distal most driver in the driver array 2800 a. Additional staple drivers 2610 a alternate with staple drivers 2910 a that are each configured to operably support a single staple 820 b thereon.

FIGS. 64-66 illustrate one exemplary form of a staple driver 2910 a with it being understood that, in at least one arrangement, a distal staple driver 2910 b essentially contains the same features as a distal staple driver 2910 a and may be a mirror image thereof. Each staple driver 2910 a, 2910 b comprises a staple driver body 2911. In the illustrated arrangement, the driver body 2911 includes a first staple support portion 2920 that is configured to support a staple 820 b thereon. As can be seen in FIG. 64, the first staple support portion 2920 comprises a first distal support column 2922 and a first proximal support column 2926. The first staple support portion 2920 further includes a first distal support cradle 2924 and a first proximal support cradle 2928 for supporting portions of the staple crown 827 b of a staple 820 b. As can be seen in FIG. 65, when the staple crown 827 b of the staple 820 b is supported on the support cradles 2924 and 2928, the distal leg 823 b is essentially axially aligned with the first distal support column 2922 and the first proximal leg 825 b is essentially axially aligned with the first proximal support column 2926. When the staple 820 b is supported on the first staple support portion 2920, the staple crown 827 b is aligned on a primary base axis PBA that is transverse to the first and second base axes of the drivers 2610 a.

In the illustrated embodiment, the staple driver 2910 a further comprises a connector portion 2990 that is configured to slidably interface with first and second driver guides 3000, 3100 that are formed in the staple cartridge. Referring to FIG. 63, a first driver guide 3000 includes a first hook-shaped portion 3002 that has a slot 3004 therein that is configured to slidably engage a support column 2652 of a corresponding staple driver 2610 a. In addition, the first driver guide 3000 includes a second hook shaped portion 3006 that has a slot 3008 that is configured to slidably engage a support column 2926 of a corresponding staple driver 2910 a. The second driver guide 3100 essentially comprises an inverted driver guide 3000. As can be seen in FIG. 63, the second driver guide 3100 includes a first hook shaped portion 3102 that has a slot 3104 that is configured to slidably engage a support column 2926 of a corresponding driver 2910 a. The second driver guide 3100 further has a second hook shaped portion 3106 that has a slot 3108 that is configured to slidably engage the support column 2922 of the corresponding driver 2910 a. As can also be seen in FIGS. 64-66, the connector portion 2990 includes a first cam portion 2992 that has a first camming surface or ramp 2994 formed thereon. The connector portion 2990 also includes a second cam portion 2996 that has a second a second camming surface 2998 formed thereon. In at least one arrangement, the camming surfaces 2994, 2998 have the same slope or angle as the corresponding camming surfaces on the drivers 2610 a. In at least one embodiment, each staple driver 2910 a, is integrally formed from or molded from, for example, Ultem®, with no fill. However, other materials such as, for example, Ultem® with a glass or mineral fill or Nylon or Nylon with a glass file could be used. In other arrangements, the various portions of the staple drivers 2910 a, 2910 b may be separately fabricated from other materials and be attached together by adhesive, solder, etc.

Referring again to FIG. 62, it can be seen that in the staple driver array 2800 a in the illustrated arrangement, the cam portion 2692 of each of the staple drivers 2610 a and the cam portion 2992 of each of the drivers 2910 a are all axially aligned along a first cam axis FCA. Thus the camming surface 2694 of each of the drivers 2610 a and the camming surface 2994 of each of the drivers 2910 a are axially aligned along the first cam axis FCA. The cam portion 2696 of each of the drivers 2610 a and the cam portion 2996 of each of the drivers 2910 a are all aligned along a second cam axis SCA. Thus, in at least one embodiment, the camming surface 2698 of each of the drivers 2610 a and the camming surface 2998 of each of the drivers 2910 a are axially aligned on the second cam axis SCA. Also in the illustrated staple driver array 2800 b, the cam portion 2692 of each of the drivers 2610 b and the cam portion 2992 of each of the drivers 2910 b are aligned along a primary cam axis PCA. Thus, the camming surface 2694 of each of the drivers 2610 b and the camming surface 2994 of each of the drivers 2910 b are axially aligned along the primary cam axis PCA. Still referring to FIG. 62, in the staple driver array 2800 b of the illustrated arrangement, the cam portion 2696 of each of the drivers 2610 b and the cam portion 2996 of each of the drivers 2910 b are all aligned along a secondary cam axis SDCA. Thus, in at least one embodiment, the camming surface 2698 of each of the drivers 2610 b and the camming surface 2998 of each of the drivers 2910 b are axially aligned on the secondary cam axis SDCA.

As can be appreciated from reference to FIG. 62, when the drivers 2610 a and 2910 a are all operably supported in the staple cartridge in the staple driver array 2800 a, the staple drivers 2610 a form a first longitudinal row 3050 a of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the first longitudinal row 3050 a extend in a first direction as was described above. Likewise, the drivers 2910 a form a second longitudinal row 3060 a of staples 820 b that are adjacent the first longitudinal row 3050 a. The staples 820 b in the second longitudinal row 3060 a extend in a second direction that is different from the first direction of the staples 820 a in the first longitudinal row 3050 a. In addition, the drivers 2610 a form a third longitudinal row 3070 a of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 3070 a is adjacent to the second longitudinal row 3060 a.

Still referring to FIG. 62, when the staple drivers 2610 b and 2910 b are all operably supported in the staple cartridge in the staple driver array 2800 b, the staple drivers 2610 b form a primary longitudinal row 3050 b of staples 820 a that is adjacent to elongate slot 804 in the cartridge body 802. Each of the staples 820 a in the primary longitudinal row 3050 b extend in a first direction as was described above. Likewise, the staple drivers 2910 b form a secondary longitudinal row 3060 b of staples 820 b that are adjacent the primary longitudinal row 3050 b. The staples 820 b in the secondary longitudinal row 3060 b extend in a second direction that is different from the first direction of the staples 820 a in the primary longitudinal row 3050 b. In addition, the staple drivers 2610 b form a tertiary longitudinal row 3070 b of staples 820 c that are oriented in a third direction which may or may not be in the same direction as staples 820 a. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 3070 b is adjacent to the secondary longitudinal row 3060 b.

Thus, when employing the staple driver arrays 2800 a, 2800 b, there are two staples extending side by side in the same direction or along parallel axes along both ends of each of the staple lines. In particular, the distal driver 2610 a supports two distal most staples in the longitudinal rows 3050 a, 3070 a that each extend in the same direction. Similarly, the proximal most driver 2610 a supports two proximal most staples in the longitudinal rows 3050 a and 3070 a of staples that extend in the same direction. Such staple pattern may provide a redundant seal arrangement at both ends of each line of staples.

Other staple driver arrays 3100 a, 3100 b are illustrated in FIGS. 67 and 68. As can be seen in those Figures, the staple driver array 3100 a employs a plurality of staple drivers 3210 a, 3310 a, 3410 a that each support a single staple thereon. Likewise, staple driver array 3100 b includes a plurality of staple drivers 3210 b, 3310 b, 3410 b. Staple drivers 3210 a may be mirror images of staple drivers 3210 b and include the same features. Staple drivers 3310 a may be mirror images of staple drivers 3310 b and include the same features. Staple drivers 3410 a may be mirror images of staple drivers 3410 b and include the same features.

As can be seen in FIG. 69, a first driver 3210 b includes a first staple supporting portion 3220 that has a distal cradle 3222 and a proximal cradle 3224 formed therein. The first staple supporting portion 3220 is configured to operably support a first staple (not shown) therein. When the first staple is supported in the first staple supporting portion 3220, the staple crown of the first staple is supported along a first base axis FBA. Also in the illustrated arrangement, a second driver 3310 b includes a second staple supporting portion 3320 that has a distal cradle 3322 and a proximal cradle 3324 formed therein. The second staple supporting portion 3320 is configured to operably support a second staple (not shown) thereon. When the second staple is supported in the second staple supporting portion 3320, the staple crown of the second staple is supported along a second base axis SBA that is transverse to the first base axis FBA. The illustrated staple driver array 3100 b also includes a third staple driver 3410 b that has a third staple supporting portion 3420. The third staple supporting portion 3420 includes a proximal cradle 3422 and a distal cradle 3424 formed therein and is configured to operably support a third staple (not shown) thereon. When the third staple is supported on the third staple supporting portion 3420, the crown of the third staple is supported along a third base axis TBA that is parallel to the first base axis FBA and transverse to the second base axis SBA.

Still referring to FIG. 69, each of the drivers 3210 b, 3310 b, 3410 b has a pair of cam portions protruding therefrom that each have a cam or ramp surface formed thereon. For example, a first driver 3210 b includes a first cam portion 3230 that has a ramp or camming surface 3232 formed thereon and a second cam portion 3234 that has a ramp or camming surface 3236 formed thereon. To provide clearance for the adjacent proximal second driver 3310 b, the proximal end 3237 of the second cam portion 3234 has an angle 3238 formed thereon as shown in FIG. 69. A second driver 3310 b includes a first cam portion 3330 that has a ramp or camming surface 3332 formed thereon and a second cam portion 3334 that has a ramp or camming surface 3336 formed thereon. To provide clearance for the adjacent proximal first driver 3210 b and adjacent proximal third driver 3410 b, the proximal end of 3331 of the first cam portion 3330 has a first angle 3333 formed thereon and the proximal end 3335 of the second cam portion 3334 has an angle 3337 formed thereon as shown in FIG. 69. A third driver 3410 b includes a first cam portion 3430 that has a ramp or camming surface 3432 formed thereon and a second cam portion 3434 that has a ramp or camming surface 3436 formed thereon. To provide clearance for the adjacent proximal second driver 3310 b, the proximal end 3431 of the first cam portion 3430 has an angle 3433 formed thereon. FIGS. 70 and 71 illustrate a second driver 3310 b to show the ramps or camming surfaces 3332, 3336 with it being understood that the first and third drivers 3210 a, 3410 a are similarly constructed.

In the illustrated embodiment, each of the drivers 3210 b, 3310 b, 3410 b has two cam portions with ramps or camming surfaces that are parallel to each other. Thus, each of the drivers 3210 b, 3310 b, 3410 b is actuated by two ramps or camming members on the sled or cam actuator. In this embodiment, however, the sled or cam actuator is formed with a total of eight ramps (four on each side of the elongate slot 804). The camming surfaces on each of the drivers 3210 b, 3310 b, 3410 b are configured at an angle that cooperates with the angle of the corresponding sled ramp or camming member to drive the respective driver upward within the staple cartridge as the sled or cam actuator is driven distally through the staple cartridge.

FIG. 72 illustrates an exemplary staple cartridge 4800 that has a cartridge body 4802 that includes an elongate slot 4804 for accommodating the tissue cutting member in the manner described herein. The elongate slot 4804 is centrally disposed along the cartridge axis CA and s bifurcates the cartridge body 4802 into two body portions 4810 and 4910. FIG. 73 illustrates a bottom perspective view of a portion of one form of the surgical staple cartridge body 802′. As can be seen in that Figure, the first body portion 4810 includes a first cartridge wall portion 4812 that includes first support grooves or slots 4814 therein that are each oriented on a corresponding first slot axis FSA that is transverse to the cartridge axis CA. The second body portion 4810 further includes a second cartridge wall portion 4820 that contains second support grooves or slots 4822 therein that are each oriented on a corresponding second slot axis SSA that is transverse to the cartridge axis CA. Located between the first cartridge wall portion 4812 and the second cartridge wall portion 4820 are four spaced slots 4830, 4832, 4834, 4836 for receiving corresponding ramps or camming members of the sled or cam actuator. Slots 4830 and 4832 define a plurality of segmented guide rails 4840 that each has a slot 4842 therein. Likewise, slots 4832 and 4834 define another plurality of segmented guide rails 4850 that each has two slots 4852 and 4854 therein. In addition, slots 4834 and 4836 define another plurality of segment guide rails 4860 that each has a slot 4862 therein.

Still referring to FIG. 73, the segmented guide rails 4840 are segmented by slots 4844 that are oriented to accommodate a staple supporting portion 3220 of a corresponding first staple driver 3210 a. In addition, the ends of the staple supporting portion 3220 are received in corresponding slots 4814 and 4852 so that each of the first drivers 3210 a is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. Similarly, the segmented guide rails 4850 are segmented by second slots 4856 that are oriented to accommodate a staple supporting portion 3320 of a corresponding second staple driver 3310 a. In addition, the ends of the staple supporting portion 3320 are received in corresponding slots 4842 and 4862 so that each of the second staple drivers 3310 a is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. Further, the segmented guide rails 4860 are segmented by third slots 4864 that are oriented to accommodate a staple supporting portion 3420 of a corresponding second staple driver 3410 a. In addition, the ends of the staple supporting portion 3420 are received in corresponding slots 4822 and 4854 so that each of the third staple drivers 3410 a is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. It will be appreciated that the slots 4844, 4856 and 4864 extend through a deck surface 4805 of the cartridge body 4802 to enable the staples to exit the cartridge body 4802. The slots 4844, 4856, 4864 may also be referred to as “staple cavities”. See FIG. 72.

Likewise, the second body portion 4910 includes a first cartridge wall portion 4912 that includes first support grooves or slots 4914 therein that each lie along a corresponding primary slot axis PSA that is transverse to the cartridge axis CA. The second body portion 4910 further includes a second cartridge wall portion 4920 that contains second support grooves or slots 4922 therein that each lie along a corresponding secondary slot axis SDSA that is transverse to the cartridge axis CA. Located between the first cartridge wall portion 4912 and the second cartridge wall portion 4920 are four spaced slots 4930, 4932, 4934, 4936 for receiving corresponding ramps or camming members of the sled or cam actuator. Slots 4930 and 4932 define a plurality of segmented guide rails 4940 that each has a slot 4942 therein. Likewise, slots 4932 and 4934 define another plurality of segmented guide rails 4950 that each has two slots 4952 and 4954 therein. In addition, slots 4934 and 4936 define another plurality of segment guide rails 4960 that each has a slot 4962 therein.

Still referring to FIG. 73, the segmented guide rails 4940 are segmented by slots 4944 that are oriented to accommodate a staple supporting portion 3220 of a corresponding first staple driver 3210 b. In addition, the ends of the staple supporting portion 3220 are received in corresponding slots 4914 and 4952 so that each of the first drivers 3210 b is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. Similarly, the segmented guide rails 4950 are segmented by second slots 4956 that are oriented to accommodate a staple supporting portion 3320 of a corresponding second staple driver 3310 b. In addition, the ends of the staple supporting portion 3320 are received in corresponding slots 4942 and 4962 so that each of the second staple drivers 3310 b is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. Further, the segmented guide rails 4960 are segmented by third slots 4964 that are oriented to accommodate a staple supporting portion 3420 of a corresponding second staple driver 3410 b. In addition, the ends of the staple supporting portion 3420 are received in corresponding slots 4922 and 4954 so that each of the third staple drivers 3410 b is completely slidably supported in the cartridge body 4802 through its range of upward travel therein. It will be appreciated that the slots 4944, 4956 and 4964 extend through the deck surface 4805 of the cartridge body 4802 to enable the staples to exit the cartridge body 4802. The slots 4944, 4956, 4964 may also be referred to as “staple cavities”. See FIG. 72.

In the illustrated arrangement, when the drivers 3210 a, 3310 a, 3410 a are installed in the cartridge body 4802 to form the staple driver array 3100 a, the cam portion 3230 of each of the first drivers 3210 a are axially aligned on a first cam axis FCA defined by the first slot 4830. Thus, the camming surfaces 3232 are also axially aligned on the first cam axis FCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. Likewise, the camming portion 3234 of each first driver 3210 a as well as each of the camming portions 3330 of the second drivers 3310 a are axially aligned on a second cam axis SCA defined by the slot 4832. Thus, the camming surfaces 3236 and 3332 are also axially aligned on the second cam axis SCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. In addition, the camming portion 3430 of each third driver 3410 a as well as each of the camming portions 3334 of each of the second drivers 3310 a are axially aligned on a third cam axis TCA defined by the slot 4834. Thus, the camming surfaces 3432 and 3336 are also axially aligned on the third cam axis TCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. Also, the camming portion 3434 of each third driver 3410 a is axially aligned on a fourth axis FTCA defined by the slot 4836. Thus, the camming surfaces 3436 are also axially aligned on the fourth cam axis FTCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator.

Also in the illustrated staple driver array 3100 b, the cam portion 3230 of each of the first drivers 3210 b are axially aligned on a primary cam axis PCA defined by the first slot 4930. Thus, the camming surfaces 3232 are also axially aligned on the first cam axis PCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. Likewise, the camming portion 3234 of each first driver 3210 b as well as each of the camming portions 3330 of the second drivers 3310 b are axially aligned on a secondary cam axis SDCA defined by the slot 4932. Thus, the camming surfaces 3236 and 3332 are also axially aligned on the secondary cam axis SDCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. In addition, the camming portion 3430 of each third driver 3410 b as well as each of the camming portions 3334 of each of the second drivers 3310 b are axially aligned on a tertiary cam axis TRCA defined by the slot 4934. Thus, the camming surfaces 3432 and 3336 are also axially aligned on the tertiary cam axis TRCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator. Also, the camming portion 3434 of each third driver 3410 a is axially aligned on another fourth axis FRCA defined by the slot 4936. Thus, the camming surfaces 3436 are also axially aligned on the another fourth cam axis FRCA for camming contact with a corresponding camming member or ramp on the sled or camming actuator.

In at least one arrangement, the camming surfaces 3232, 3236, 3332, 3336, 3432, 3436 may be formed with identical slopes or angles or they may have different slopes. However, in the illustrated arrangement, for example, the camming surfaces 3232 are oriented or otherwise configured to operably match the angle/orientation of the camming member or ramp of the sled or camming actuator. Also in the illustrated arrangement, the camming surfaces 3236 and 3332 are formed with the same slope or angle and/or are otherwise configured to operably match the angle/orientation of the corresponding camming member or ramp of the sled or camming actuator. However, it is conceivable that the angle or slope of the camming surfaces 3236, 3332 are not the same as the angle or slope of the camming surfaces 3232. Likewise, the camming surfaces 3432 and 3336 are formed with the same slope or angle and/or are otherwise configured to operably match the angle/orientation of the corresponding camming member or ramp of the sled or camming actuator. However, it is conceivable that the angle or slope of the camming surfaces 3432, 3336 are not the same as the angle or slope of the camming surfaces 3232, 3234, 3332. Also in the illustrated arrangement, the camming surfaces 3436 are formed with the same slope or angle and/or are otherwise configured to operably match the angle/orientation of the corresponding camming member or ramp of the sled or camming actuator. However, it is conceivable that the angle or slope of the camming surfaces 3436 is not the same as the angle or slope of the camming surfaces 3232, 3234, 3332, 3432, 3336.

Still referring to FIG. 67, when the staple drivers 3210 a, 3310 a, 3410 a are all operably supported in the staple cartridge in the staple driver array 3100 a, the staple drivers 3210 a form a first longitudinal row 5000 a of staples that is adjacent to elongate slot 804 in the cartridge body 4802. Each of the staples in the first longitudinal row 5000 a extend in a first direction as was described above. Likewise, the staple drivers 3310 a form a second longitudinal row 5010 a of staples that are adjacent the first longitudinal row 5000 a. The staples in the second longitudinal row 5010 a extend in a second direction that is different from the first direction of the staples in the first longitudinal row 5000 a. In addition, the staple drivers 3410 a form a third longitudinal row 5020 a of staples that are oriented in a third direction which may or may not be in the same direction as the staples in the second longitudinal row 5010 a. For example, in the illustrated embodiment, the first and third directions are the same. The third longitudinal row 5020 a is adjacent to the second longitudinal row 5010 a.

In the illustrated arrangement, when the staple drivers 3210 b, 3310 b, 3410 b are all operably supported in the staple cartridge in the staple driver array 3100 b, the staple drivers 3210 b form a primary longitudinal row 5000 b of staples that is adjacent to elongate slot 804 in the cartridge body 4802. Each of the staples in the primary longitudinal row 5000 b extend in a first direction as was described above. Likewise, the staple drivers 3310 b form a secondary longitudinal row 5010 b of staples that are adjacent the primary longitudinal row 5000 b. The staples in the secondary longitudinal row 5010 b extend in a second direction that is different from the first direction of the staples in the primary longitudinal row 5000 b. In addition, the staple drivers 3410 b form a tertiary longitudinal row 5020 b of staples that are oriented in a third direction which may or may not be in the same direction as staples in the secondary longitudinal row 5010 b. For example, in the illustrated embodiment, the first and third directions are the same. The tertiary longitudinal row 5020 b is adjacent to the secondary longitudinal row 5010 b.

FIG. 74 illustrates a portion of another surgical staple cartridge 6000 that is configured to achieve lines of staples that each have different formed heights and that may employ various staple driver array arrangements disclosed herein. The surgical staple cartridge 6000 includes a cartridge body 6002 that has an elongate slot 6004 that divides the cartridge body into a first cartridge portion 6010 and a second cartridge portion 6110. The first cartridge portion 6010 includes a “stepped deck” 6012. In the illustrated example, the lowest deck surface or “first” deck portion is designated as 6020. A series of slots or first staple pockets 6022 that are configured to support a first longitudinal line 6030 of first surgical staples 7000 are provided in the first deck portion 6020. In the illustrated embodiment, the first staple pockets 6022 in the line 6030 are parallel to each other and are each oriented on a corresponding first axis FA.

As can be further seen in FIG. 74, the stepped deck 6012 further includes a second deck portion 6040 that has a height or thickness “T1”. Stated another way, the second deck portion 6040 extends above the first deck portion 6020 the thickness T1. In one example, T1 may be approximately 0.01 inches. However, other thicknesses or height differences may be employed. For example, T1 may range from 0.005 inches-0.025 inches. A second series of slots or second staple pockets 6042 are oriented in the second deck portion 6040 to support a second line 6050 of second staples 7020 therein. The second staple pockets 6042 are parallel to each other and are each aligned on a second axis SA. The second axes may be transverse to the first axes FA.

Still referring to FIG. 74, the first stepped deck 6012 further includes a third deck portion 6060 that has a height or thickness “T2”. Stated another way, the third deck portion 6060 extends above the first deck portion 6020 the thickness T2. In one example, T2 may be approximately 0.02 inches. However, other thicknesses or height differences may be employed. For example, T1 may range from 0.005 inches-0.030 inches. A third series of slots or second staple pockets 6062 are oriented in the third deck portion 6060 to support a third line 6070 of third staples 7020 therein. The third staple pockets 6062 are parallel to each other and are each aligned on a third axis TA. The third axes may be parallel to the first axes FA and transverse to the second axes SA, for example.

In use, when the anvil of the surgical instrument is locked in a closed position wherein the staple forming undersurface of the anvil is positioned in confronting relationship with the deck of the staple cartridge 6000, the third deck portion 6070 will be closer to the undersurface of the anvil than the second deck portion 6040 and the first deck portion 6020. Likewise, the second deck portion 6040 is closer to the staple forming undersurface of the anvil than the first deck portion 6020. Thus, as illustrated in FIG. 75, the third staples 7030 supported in the third staple pockets 6062 will have a third forming height “TFH” that is less than the second forming height “SFH” of the second staples 7020 supported in the second staple pockets 6042 and second forming height SFH of the second staples 7020 is less than the first forming height “FFH” of the staples supported in the first staple pockets 6022. As shown in FIG. 74, the line 6070 of third staples 7030 may be adjacent to the elongate slot 6004. Thus, the staples 7030 that are the closest to the cut line in the tissue will have the shortest formed height.

The second cartridge portion 6110 includes a primary deck portion 6120 that is the lowest deck surface. A series of slots or primary staple pockets 6122 that are configured to support a primary longitudinal line 6130 of first surgical staples 7000 are provided in the primary deck portion 6120. In the illustrated embodiment, the primary staple pockets 6122 in the primary line 6130 are parallel to each other and are each oriented on a corresponding primary axis PA. As can be further seen in FIG. 74, the stepped deck 6012 further includes a secondary deck portion 6140 that has a height or thickness “T1′”. Stated another way, the secondary deck portion 6140 extends above the primary deck portion 6120 the thickness T1′. In the illustrated arrangement T1′ is equal to T1. However, other arrangements are contemplated wherein T1′ does not equal T1. A second series of slots or second staple pockets 6142 are oriented in the secondary deck portion 6140 to support a secondary line 6150 of second staples 7020 therein. The secondary staple pockets 6142 are parallel to each other and are each aligned on a secondary axis SDA. The secondary axes SDA may be transverse to the primary axes PA.

Still referring to FIG. 74, the stepped deck 6012 further includes a tertiary deck portion 6160 that has a height or thickness “T2′”. Stated another way, the tertiary deck portion 6160 extends above the primary deck portion 6120 the thickness T2′. In the illustrated arrangement, T2′ is equal to T2. However, other arrangements are contemplated wherein T2′ does not equal T2. A tertiary series of slots or tertiary staple pockets 6162 are oriented in the tertiary deck portion 6160 to support a tertiary line 6170 of third staples 7030 therein. The tertiary staple pockets 6162 are parallel to each other and are each aligned on a tertiary axis TRA. The tertiary axes TRA may be parallel to the primary axes PA and transverse to the secondary axes SDA, for example.

In use, when the anvil of the surgical instrument is locked in a closed position wherein the staple forming undersurface of the anvil is positioned in confronting relationship with the deck of the staple cartridge 6000, the tertiary deck portion 6160 will be closer to the undersurface than the second deck portion 6040 and the first deck portion 6020. Likewise, the secondary deck portion 6140 is closer to the staple forming undersurface of the anvil than the primary deck portion 6120. Thus, as illustrated in FIG. 75, the third staples 7030 supported in the third staple pockets 6062 will have a third forming height “TFH” that is less than the second forming height “SFH” of the second staples 7020 supported in the secondary staple pockets 6142 and second forming height SFH of the second staples 7020 is less than the first forming height “FFH” of the staples supported in the primary staple pockets 6122. As shown in FIG. 74, the line 6170 of third staples 7030 may be adjacent to the elongate slot 6004. Thus, the staples 7030 that are the closest to the cut line in the tissue will have the shortest formed height.

Various staple driver arrangements disclosed herein may be effectively employed with the above-described stepped deck arrangement to achieve staples having different formed heights. All of the various driver combinations and stepped deck configurations are contemplated herein. The various staples employed may start with different unformed heights. For example, all of the staples in one line of staples may have the same height, but have a different height than all of the staples in another line or other lines of staples in the cartridge. The staples may be U-shaped or be V-shaped. The staples may have different wire diameters. Further details regarding staple configurations, cartridge and driver arrangements for forming staples with different formed heights are disclosed in U.S. Pat. No. 7,669,746, entitled STAPLE CARTRIDGES FOR FORMING STAPLES HAVING DIFFERENT FORMED HEIGHTS; U.S. Pat. No. 7,500,979, entitled SURGICAL STAPLING DEVICE WITH MULTIPLE STACKED ACTUATOR WEDGE CAMS FOR DRIVING STAPLE DRIVERS; U.S. Pat. No. 7,673,781, entitled SURGICAL STAPLING DEVICE WITH STAPLE DRIVER THAT SUPPORTS MULTIPLE WIRE DIAMETER STAPLES; U.S. Pat. No. 8,636,187, entitled SURGICAL STAPLING SYSTEMS THAT PRODUCE FORMED STAPLES HAVING DIFFERENT LENGTHS; U.S. Pat. No. 7,934,630, entitled STAPLE CARTRIDGES FOR FORMING STAPLES HAVING DIFFERENT FORMED HEIGHTS; U.S. Pat. No. 8,567,656, entitled STAPLE CARTRIDGES FOR FORMING STAPLES HAVING DIFFERENT FORMED HEIGHTS; U.S. Pat. No. 8,464,923, entitled STAPLE CARTRIDGES FOR FORMING STAPLES HAVING DIFFERENT FORMED HEIGHTS, the entire disclosures of each being hereby incorporated by reference herein.

As the present Detailed Description proceeds, it will be understood that the various forms of surgical staple cartridges disclosed herein may also be effectively employed in connection with robotically-controlled surgical systems. Thus, the term “housing” may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system that is configured to generate and apply at least one control motion which could be used to actuate the elongate shaft assemblies disclosed herein and their respective equivalents. The term “frame” may refer to a portion of a handheld surgical instrument. The term “frame” may also represent a portion of a robotically controlled surgical instrument and/or a portion of the robotic system that may be used to operably control a surgical instrument. For example, the shaft assemblies disclosed herein may be employed with various robotic systems, instruments, components and methods disclosed in U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, which is hereby incorporated by reference herein in its entirety.

The surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. The motor or motor(s) may comprise a portion or portions of a robotically controlled system.

The surgical instrument systems described herein are motivated by one or more electric motors; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example.

EXAMPLES Example 1

A surgical staple driver array for operable use with a surgical staple cartridge. In at least one configuration, the surgical staple driver array comprises a distal staple driver that is slidably supportable in the surgical staple cartridge and is configured to operably support a single distal surgical staple thereon that is oriented in a distal direction. A plurality of intermediate staple drivers is configured to be slidably supported in the surgical staple cartridge in series, wherein a distal most one of the intermediate staple drivers is adjacent to the distal staple driver. Each of the intermediate staple drivers is configured to operably support a first surgical staple that is oriented in a first direction as well as a second surgical staple that is oriented in a second direction and a third surgical staple that is oriented in a third direction. A proximal staple driver is slidably supported adjacent a proximal most one of the intermediate staple drivers. The proximal staple driver is configured to operably support a proximal surgical staple that is oriented in a proximal direction.

Example 2

The surgical staple driver array of Example 1, wherein the distal direction is parallel to at least one of the first, second and third directions.

Example 3

The surgical staple driver array of Examples 1 or 2, wherein the proximal direction is parallel to at least one of the first, second and third directions.

Example 4

The surgical staple driver array of Examples 1, 2 or 3, wherein the distal direction, the first direction, the third direction and the proximal direction are parallel to each other.

Example 5

The surgical staple driver array of Examples 1, 2, 3 or 4, wherein a distal crown of the distal surgical staple is supported along a distal base axis and a first crown of the first surgical staple is supported along a first base axis that is parallel to the distal base axis.

Example 6

The surgical staple driver array of Example 5, wherein a second staple crown of the second surgical staple is supported along a second base axis that is transverse to the first base axis.

Example 7

The surgical staple driver array of Examples 5 or 6, wherein a third staple crown of the third surgical staple is supported along a third base axis that is parallel to the first base axis.

Example 8

The surgical staple driver array of Example 7, wherein a proximal staple crown of the proximal surgical staple is supported along a proximal base axis that is parallel to the third base axis of the third surgical staple supported in the proximal most one of the intermediate staple drivers.

Example 9

A surgical staple cartridge that comprises a cartridge body that comprises a proximal end and a distal end. A distal staple driver is movably supported in the cartridge body and is configured to support a single, distal most surgical staple thereon that is oriented in a distal direction. A plurality of intermediate staple drivers is movably supported in the cartridge body in series, wherein a distal most one of the intermediate staple drivers is adjacent to the distal staple driver. Each intermediate staple driver supports a first surgical staple in a first direction, a second surgical staple in a second direction and a third surgical staple in a third direction. A proximal staple driver is slidably supported adjacent a proximal most one of the intermediate staple drivers. The proximal staple driver is configured to operably support a proximal surgical staple that is oriented in a proximal direction.

Example 10

The surgical staple cartridge of Example 9, wherein a distal crown of the distal surgical staple is supported along a distal base axis and a first crown of the first surgical staple is supported along a first base axis that is parallel to the distal base axis. A second staple crown of the second surgical staple is supported along a second base axis that is transverse to the first base axis. A third staple crown of the third surgical staple is supported along a third base axis that is parallel to the first base axis. A proximal staple crown of the proximal surgical staple is supported along a proximal base axis that is parallel to the third base axis of the third surgical staple that is supported in the proximal most intermediate staple driver.

Example 11

The surgical staple cartridge of Examples 9 or 10, wherein the distal staple driver comprises a distal staple support member that comprises a distal support column that is configured to support a distal leg of the distal surgical staple thereon. The distal staple support member further comprises a proximal support column that is configured to support a proximal leg of the distal surgical staple thereon. One of the distal and proximal support columns is slidably supported in one of a first wall portion and a second wall portion of the cartridge body.

Example 12

The surgical staple cartridge of Example 11, wherein the distal staple driver further comprises a distal camming surface that is aligned on a first cam axis that extends transversely between the distal and proximal support columns.

Example 13

The surgical staple cartridge of Examples 9, 10, 11 or 12, wherein at least one of the intermediate staple drivers comprises a first staple support member that comprises a first distal support column that is configured to support a first distal leg of a corresponding first surgical staple thereon. The first staple support member further comprises a first proximal support column that is configured to support a first proximal leg of the corresponding first surgical staple thereon. The intermediate staple driver further comprises a second staple support member that comprises a second distal support column that is configured to support a second distal leg of a corresponding second surgical staple thereon. The second staple support member further comprises a second proximal support column that is configured to support a second proximal leg of the corresponding second surgical staple thereon. The intermediate staple driver further comprises a third staple support member that comprises a third distal support column that is configured to support a third distal leg of a corresponding third surgical staple thereon. The third staple support member further comprises a third proximal support column that is configured to support a third proximal leg of the corresponding third surgical staple thereon. One of the third distal support column and the third proximal support column is slidably supported in one of first and second wall portions of the cartridge body.

Example 14

The surgical staple cartridge of Examples 9, 10, 11, 12 or 13, wherein the proximal staple driver comprises a proximal staple support member that comprises another distal support column that is configured to support another distal leg of the proximal surgical staple thereon. The proximal staple support member further comprises another proximal support column that is configured to support another proximal leg of the proximal surgical staple thereon. One of the another distal and the another proximal support columns is slidably supported in one of a first wall portion and a second wall portion of the cartridge body.

Example 15

The surgical staple cartridge of Example 14, further comprising at least one distal camming surface on the distal staple support member and at least one first camming surface on at least one of the first, second and third staple support members. At least one proximal camming surface is on the proximal staple support member.

Example 16

The surgical staple cartridge of Example 15, wherein the at least one distal camming surface, the at least one first camming surface and the at least one proximal camming surface are aligned on a common camming axis.

Example 17

The surgical staple cartridge of Examples 15 or 16, wherein the at least one distal camming surface comprises a first distal camming surface and a second distal camming surface that is spaced from the first distal camming surface. The first camming surface comprises a first camming surface and a second camming surface that is spaced from the first camming surface. At least one proximal camming surface comprises a first proximal camming surface and a second proximal camming surface.

Example 18

The surgical staple cartridge of Example 17, wherein the first distal camming surface, the first camming surface and the first proximal camming surface are aligned on a first camming axis and wherein the second distal camming surface, the second camming surface and the second proximal camming surface are aligned on a second camming axis.

Example 19

The surgical staple cartridge of Example 18, wherein the first camming surface is on the first staple support member and the second camming surface is on the third staple support member.

Example 20

A surgical instrument, comprising an axially movable sled that comprises first and second camming members. The surgical instrument further comprises a surgical staple cartridge and at least one distal staple driver that is movably supported in the surgical staple cartridge. Each distal staple driver is configured to operably support a corresponding distal staple thereon and comprises a first distal camming surface that is aligned for camming contact with the first camming member and a second distal camming surface that is aligned for camming contact with the second camming member. A plurality of intermediate staple drivers is movably supported in the surgical staple cartridge in series. A distal most one of the intermediate staple drivers is adjacent to one of the at least one distal staple drivers. Each of the intermediate staple drivers supports a corresponding first surgical staple, a corresponding second surgical staple and a corresponding third surgical staple thereon. Each intermediate staple driver comprises a first camming surface that is aligned for camming contact with the first camming member and a second camming surface that is aligned for camming contact with the second camming member. A proximal staple driver is slidably supported adjacent a proximal most one of the intermediate staple drivers. The proximal staple driver is configured to operably support a corresponding proximal surgical staple thereon and comprises a first proximal camming surface that is aligned for camming contact with the first camming member and a second proximal camming surface that is aligned for camming contact with the second camming member.

Example 21

A surgical staple driver array for operable use with a surgical staple cartridge. In at least one form, the surgical staple driver array comprises a distal staple driver that is configured to be slidably supported in the surgical staple cartridge. The surgical staple driver array is also configured to operably support at least two distal surgical staples thereon that are each oriented in a distal direction. At least one first intermediate staple driver is configured to be slidably supported in the surgical staple cartridge. The intermediate staple driver operably supports at least two first surgical staples that are each oriented in a first direction and at least two second surgical staples that are each oriented in a second direction that differs from the first direction. At least one second intermediate staple driver is configured to be slidably supported adjacent at least one of the distal staple drivers and a corresponding one of the at least one first intermediate staple drivers. Each of the at least one second intermediate staple drivers is configured to operably support five, second surgical staples thereon wherein at least two of the second surgical staples are each oriented in a primary direction and at least one other of the second surgical staples is oriented in a secondary direction that differs from the primary direction.

Example 22

The surgical staple driver array of Example 21, wherein at least one of the first and second directions is parallel to the distal direction.

Example 23

The surgical staple driver array of Examples 21 or 22, wherein the first and second directions are transverse to each other.

Example 24

The surgical staple driver array of Examples 21, 22 or 23, wherein at least one of the primary and secondary directions is parallel to the distal direction.

Example 25

The surgical staple driver array of Examples 21, 22, 23 or 24, wherein four of the second surgical staples are oriented in the primary direction and one other of the second staples is oriented in the secondary direction.

Example 26

The surgical staple driver array of Examples 21, 22, 23, 24 or 25, wherein one of the distal surgical staples comprises a distal crown that is aligned on a first distal base axis and another of the distal surgical staples comprises another distal crown that is aligned on a second distal base axis that is parallel to the first distal base axis. One of the first surgical staples comprises a first staple crown that is aligned on a first base axis and another one of the first surgical staples comprises another first staple crown that is aligned on another first base axis that is parallel to the first base axis. One of the second surgical staples comprises a second staple crown that is aligned on a second base axis and another of the second surgical staples comprises another second staple crown that is aligned on another second base axis that is parallel to the second base axis.

Example 27

The surgical staple driver array of Example 26, wherein the first and second distal base axes are parallel with the first base axis and the another first base axis and wherein the second base axis and the another second base axis are transverse to the first base axis and the another first base axis.

Example 28

The surgical staple driver array of Examples 21, 22, 23, 24, 25, 26 or 27, wherein the distal staple driver comprises at least one distal camming surface and wherein at least one of the at least one first intermediate staple drivers comprises at least one first camming surface and wherein at least one of the at least one second intermediate staple drivers comprises at least one primary camming surface and wherein the at least one distal camming surface and the at least one first camming surface and the at least one primary camming surface are axially aligned along a first camming axis.

Example 29

The surgical staple driver array of Example 28, wherein the distal staple driver comprises a first distal camming surface and a second distal camming surface that is spaced from the first distal camming surface. Each of the at least one first intermediate staple drivers comprises a first camming surface and a second camming surface that is spaced from the first camming surface. Each of the at least one second intermediate staple drivers comprises a primary camming surface and a secondary camming surface that is spaced from the primary camming surface. The first distal camming surface, each of the first camming surfaces and each of the primary camming surfaces are axially aligned on the first camming axis. The second distal camming surface, each of the second camming surfaces and each of the secondary camming surfaces are axially aligned on a second camming axis.

Example 30

A surgical staple cartridge, comprising a cartridge body that comprises a proximal end and a distal end. A distal staple driver is movably supported in the cartridge body and is configured to support at least two distal surgical staples thereon. Each of the distal surgical staples extends in a distal direction. At least one first intermediate staple driver is movably supported in the cartridge body. Each of the first intermediate staple drivers is configured to support at least two first surgical staples that each extends in a first direction and at least two other first surgical staples that each extend in a second direction. The surgical staple cartridge further comprises at least one second intermediate staple driver that is configured to be slidably supported adjacent to at least one of the distal staple drivers and a corresponding one of the first intermediate staple drivers. Each second intermediate staple driver is configured to operably support five other surgical staples thereon wherein at least two of the other surgical staples are each oriented in a primary direction and at least a third one of the other surgical staples is oriented in a secondary direction that differs from the primary direction.

Example 31

The surgical staple cartridge of Example 30, wherein a first one of the distal surgical staples comprises a first distal crown that is aligned on a first distal base axis and wherein a second one of the distal surgical staples comprises a second distal crown that is aligned on a second distal base axis that is parallel to the first distal base axis. At least one of the first surgical staples comprises a first staple crown that is aligned on a first base axis and wherein at least one other of the first surgical staples comprises another first staple crown that is aligned on another first base axis that is parallel to the first base axis. At least one of the second surgical staples comprises a second staple crown that is aligned on a second base axis and at least one other of the second surgical staples comprises another second staple crown that is aligned on another second base axis that is parallel to the second base axis.

Example 32

The surgical staple cartridge of Examples 30 or 31, wherein the distal staple driver comprises a distal staple support member that comprises a distal support column that is configured to support a distal leg of a distal surgical staple thereon. The distal staple driver further comprises a proximal support column that is configured to support a proximal leg of the distal surgical staple thereon. The distal staple driver also comprises another distal staple support member that comprises another distal support column that is configured to support another distal leg of another distal surgical staple thereon. The another distal staple support member further comprises another proximal support column that is configured to support another proximal leg of the another distal surgical staple thereon.

Example 33

The surgical staple cartridge of Example 32, wherein one of the distal support column and another distal support column is slidably supported in one of first and second cartridge wall portions in the cartridge body and wherein one of the proximal support column and another proximal support column is slidably supported in the other one of the first and second cartridge wall portions.

Example 34

The surgical staple cartridge of Examples 32 or 33, wherein the distal staple driver further comprises a first distal camming surface on the first distal staple support member and a second distal camming surface on the second distal staple support member.

Example 35

The surgical staple cartridge of Examples 30, 31, 32, 33 or 34, wherein at least one of the first intermediate staple drivers comprises a first staple support member that comprises a first distal support column that is configured to support a first distal leg of a corresponding first surgical staple thereon. The first staple support member further comprises a first proximal support column that is configured to support a first proximal leg of the corresponding first surgical staple thereon. The at least one of the first intermediate staple drivers further comprises a second staple support member that comprises a second distal support column that is configured to support a second distal leg of a corresponding second surgical staple thereon. The second staple support member further comprises a second proximal support column that is configured to support a second proximal leg of the corresponding second surgical staple thereon. The at least one of the first intermediate staple drivers also comprises a third staple support member that comprises a third distal support column that is configured to support a third distal leg of a corresponding third surgical staple thereon. The third staple support member further comprises a third proximal support column that is configured to support a third proximal leg of the corresponding third surgical staple thereon. The at least one of the first intermediate staple drivers further comprises a fourth staple support member that comprises a fourth distal support column that is configured to support a fourth distal leg of a corresponding fourth surgical staple thereon. The fourth staple support member further comprises a fourth proximal support column that is configured to support a fourth proximal leg of the corresponding fourth surgical staple thereon. A first crown of the corresponding first surgical staple and a second crown of the corresponding second surgical staple are parallel to each other. A third crown of the corresponding third surgical staple and a fourth crown of the fourth corresponding surgical staple are parallel to each other and transverse to the first and second crowns.

Example 36

The surgical staple cartridge of Example 35, wherein one of the first distal support column and the third proximal support column is slidably supported in one of first and second cartridge wall portions in the cartridge body and wherein the other one of the first distal support column and the third proximal support column is slidably supported in the other one of the first and second cartridge wall portions.

Example 37

The surgical staple cartridge of Examples 30, 31, 32, 33, 34, 35 or 36, wherein at least one of the second intermediate staple drivers comprises another first staple support member that comprises another first distal support column that is configured to support another first distal leg of a corresponding first other surgical staple thereon. The another first staple support member further comprises another first proximal support column that is configured to support another first proximal leg of the corresponding first other surgical staple thereon. The second intermediate staple driver further comprises another second staple support member that comprises another second distal support column that is configured to support another second distal leg of a corresponding second other surgical staple thereon. The another second staple support member further comprises another second proximal support column that is configured to support another second proximal leg of the corresponding second other surgical staple thereon. The second intermediate staple driver further comprises another third staple support member that comprises another third distal support column that is configured to support another third distal leg of a corresponding third other surgical staple thereon. The another third staple support member further comprises another third proximal support column that is configured to support another third proximal leg of the corresponding third other surgical staple thereon. The second intermediate staple driver further comprises another fourth staple support member that comprises another fourth distal support column that is configured to support another fourth distal leg of a corresponding fourth other surgical staple thereon. The another fourth staple support member further comprises another fourth proximal support column that is configured to support another fourth proximal leg of the corresponding fourth other surgical staple thereon. Another first crown of the first corresponding other surgical staple and another second crown of the second corresponding other surgical staple and another third crown of the third corresponding other surgical staple and another fourth crown of the fourth corresponding other surgical staple are parallel to each other. The second intermediate staple driver further comprises a fifth staple support member that comprises a fifth distal support column that is configured to support a fifth distal leg of a corresponding fifth other surgical staple thereon. The fifth staple support member further comprises a fifth proximal support column that is configured to support a fifth proximal leg of the corresponding fifth other surgical staple thereon. A fifth crown of the fifth corresponding other surgical staple is transverse to the another first crown, the another second crown, the another third crown and the another fourth crown.

Example 38

The surgical staple cartridge of Example 37, wherein the another first proximal support column and the another third proximal support column are each slidably supported in one of first and second cartridge wall portions of the cartridge body and wherein the another second proximal support column and the another fourth proximal support column are each slidably supported in the other one of the first and second cartridge wall portions.

Example 39

The surgical staple cartridge of Examples 37 or 38, further comprising a primary camming surface that is located adjacent to the another first proximal support column and the another third proximal support column and is located inboard relative thereto. A secondary camming surface is located adjacent to the another second proximal support column and the another fourth proximal support column and is located inboard relative thereto.

Example 40

A surgical instrument, comprising an axially movable sled that comprises first and second camming members. The surgical instrument further comprises a surgical staple cartridge and at least one distal staple driver that is movably supported in the surgical staple cartridge. Each distal staple driver is configured to operably support two distal surgical staples thereon and comprises a first distal camming surface that is aligned for camming contact with the first camming member. Each distal staple driver further comprises a second distal camming surface that is aligned for camming contact with the second camming member. At least one first intermediate staple driver is movably supported in the surgical staple cartridge and supports four surgical staples thereon. Each first intermediate staple driver comprises a first camming surface that is aligned for camming contact with the first camming member and a second camming surface that is aligned for camming contact with the second camming member. The surgical instrument further comprises at least one second intermediate staple driver that is slidably supported in the surgical staple cartridge adjacent at least one of the distal staple driver and a corresponding one of the first intermediate staple drivers. Each second intermediate staple driver is configured to operably support at least five other surgical staples thereon and comprises a first proximal camming surface that is aligned for camming contact with the first camming member. Each of the second intermediate staple drivers further comprises a second proximal camming surface that is aligned for camming contact with the second camming member.

Example 41

A surgical staple driver comprising a driver body that is configured to be slidably supported in a surgical staple cartridge. In at least one form, the driver body comprises at least two staple support members wherein each staple support member is configured to operably support a corresponding surgical staple thereon. The driver body further comprises a first camming surface and a second camming surface that is spaced from the first camming surface. The driver body further comprises at least one aperture that is configured to slidably receive therein a corresponding driver guide formed in the surgical staple cartridge.

Example 42

The surgical staple driver of Example 41, wherein each of the at least one apertures is located between the first and second camming surfaces.

Example 43

The surgical staple driver of Examples 41 or 42, wherein the driver body comprises a distal end and a proximal end and wherein at least one of the proximal end and the distal end is configured to slidably engage another one of the corresponding driver guides.

Example 44

The surgical staple driver of Examples 41, 42, or 43, wherein one of the at least two staple support members supports a corresponding surgical staple along a base axis and wherein another one of the staple support members supports another surgical staple along another base axis that is parallel with the base axis.

Example 45

The surgical staple driver of Example 44, wherein the another base axis is transverse to the base axis.

Example 46

The surgical staple driver of Examples 41, 42, 43, 44, or 45, wherein one of the staple support members comprises a proximal support column that is configured to support a proximal leg of a corresponding surgical staple thereon. The staple support member further comprises a distal support column that is configured to support a distal leg of the corresponding surgical staple thereon. Another one of the staple support members comprises another proximal support column that is configured to support another proximal leg of another corresponding surgical staple thereon. The another staple support member further comprises another distal support column that is configured to support another distal leg of the another corresponding surgical staple thereon. One of the proximal support column and the distal support column is slidably supported in a corresponding slot in a wall portion of the surgical staple cartridge. One of the another proximal support column and the another distal support column is slidably supported in another corresponding slot in another cartridge wall portion of the surgical staple cartridge.

Example 47

The surgical staple driver of Example 46, wherein the surgical staple cartridge defines a cartridge axis and wherein the corresponding slot and the another corresponding slot are each transverse to the cartridge axis.

Example 48

The surgical staple driver of Example 47, wherein the corresponding driver guide is centrally disposed between the cartridge wall portion and the another cartridge wall portion.

Example 49

A surgical staple cartridge, comprising a cartridge body that defines a cartridge axis and comprises a first cartridge wall and a second cartridge wall spaced from the first cartridge wall. The cartridge body further comprises at least two upstanding driver guides that are located between the first cartridge wall and the second cartridge wall. The surgical staple cartridge further comprises at least one surgical staple driver that comprises a driver body that comprises a proximal end that is configured to slidably engage one of the driver guides and a distal end that is configured to slidably engage another one of the driver guides. The driver body further comprises at least one staple support member that is configured to operably support a surgical staple thereon.

Example 50

The surgical staple cartridge of Example 49, wherein the at least one staple support member comprises a first staple support member that is configured to support a first surgical staple thereon and a second staple support member that is configured to support a second surgical staple thereon. A portion of the first staple support member is slidably supported in a corresponding slot in the first cartridge wall and another portion of the second staple support member is slidably supported in another corresponding slot in the second cartridge wall.

Example 51

The surgical staple cartridge of Example 50, wherein the corresponding slot and the another corresponding slot are each transverse to the cartridge axis.

Example 52

The surgical staple cartridge of Examples 49, 50 or 51, wherein the first surgical staple comprises a first crown supported on a first base axis and wherein the second surgical staple comprises a second crown on a second base axis that is parallel with the first base axis.

Example 53

The surgical staple cartridge of Example 52, wherein the second base axis is transverse to the first base axis.

Example 54

The surgical staple cartridge of Examples 49, 50, 51 or 52 wherein each surgical staple driver further comprises at least one aperture therein that is configured to slidably receive a corresponding additional driver guide therein.

Example 55

A surgical instrument, comprising an axially movable sled that comprises a first camming member that is configured to move along a first cam axis and a second camming member that configured to move along a second cam axis. The surgical instrument further comprises a surgical staple cartridge that comprises a cartridge body that comprises a first cartridge wall and a second cartridge wall that is spaced from the first cartridge wall. The cartridge body further comprises at least two upstanding staple guides that are located between the first cartridge wall and the second cartridge wall. The surgical instrument further comprises at least one surgical staple driver that comprises a driver body that comprises a proximal end that is configured to slidably engage one of the driver guides and a distal end that is configured to slidably engage another one of the driver guides. The surgical staple driver further comprises at least one staple support members that is configured to operably support a surgical staple thereon.

Example 56

The surgical instrument of Examples 55, wherein the driver body further comprises a first camming surface that is oriented on one side of each of the driver guides and is in axial alignment with the first cam axis and a second camming surface that is oriented on another side of each of the driver guides and is in axial alignment with the second cam axis.

Example 57

The surgical instrument of Example 55, wherein the driver body further comprises at least one aperture therein that is located between the first and second camming surfaces and is configured to slidably receive a corresponding additional driver guide therein.

Example 58

The surgical instrument of Examples 55, 56 or 57, wherein the at least one staple support member comprises a first staple support member that is configured to support a first surgical staple thereon and a second staple support member that is configured to support a second surgical staple thereon. A portion of the first staple support member is slidably supported in the first cartridge wall and another portion of the second staple support member is slidably supported in the second cartridge wall.

Example 59

The surgical instrument of Examples 55, 56, 57 or 58, wherein the surgical staple cartridge defines a cartridge axis and wherein the corresponding slot and the another corresponding slot are each transverse to the cartridge axis.

Example 60

The surgical instrument of Example 54, 55, 56, 57, 58 or 59, wherein the at least one staple support member comprises a first staple support member that is configured to support a first surgical staple thereon and a second staple support member that is configured to support a second surgical staple thereon. A portion of the first staple support member is slidably supported in the first cartridge wall and another portion of the second staple support member is slidably supported in the second cartridge wall.

Example 61

A surgical staple driver that is configured for use with a surgical staple cartridge that operably interfaces with a surgical instrument camming member that is axially movable along a first cam axis. In at least one form, the surgical staple driver comprises a driver body that is slidably supportable within the surgical staple cartridge. A camming surface is provided on the driver body and is oriented for camming engagement with the camming member of the surgical instrument along the first cam axis when the driver body is slidably supported in the surgical staple cartridge. A staple support portion is configured to operably support at least one surgical staple thereon relative to the camming surface such that when the camming member engages the camming surface, the camming member passes transversely under a portion of a staple crown of at least one of the at least one surgical staples that is supported on the staple support portion.

Example 62

The surgical staple driver of Example 61, wherein each of the at least one surgical staples that is supported on the staple supporting portion comprises a proximal leg that protrudes from the staple crown and a distal leg that protrudes from the staple crown. The staple support portion also supports the at least one surgical staple thereon relative to the camming surface such that when the camming member engages the camming surface, the camming member is not in axial alignment with the proximal and distal legs of any of the surgical staples supported on the staple support portion.

Example 63

The surgical staple driver of Examples 61 or 62, wherein the staple support portion comprises a first staple support portion that is configured to operably support a first surgical staple thereon. The first surgical staple comprises a first staple crown. A first distal leg protrudes from an end of the first staple crown and a first proximal leg protrudes from another end of the first staple crown. The first staple support portion operably supports the first staple crown along a first base axis that is transverse to the first cam axis and comprises a first proximal support column that is configured to support the first proximal leg of the first surgical staple thereon. The first staple support portion further comprises a first distal support column that is configured to support the first distal leg of the first surgical staple thereon. The camming surface is oriented relative to the first proximal support column and the first distal support column such that when the camming member engages the camming surface, the camming member passes between the first proximal support column and the first distal support column.

Example 64

The surgical staple driver of Example 63, wherein the staple support portion further comprises a second staple support portion that is configured to operably support a second surgical staple thereon. The second surgical staple comprises a second staple crown. A second distal leg protrudes from an end of the second staple crown and a second proximal leg protrudes from another end of the second staple crown. The second staple support portion comprises a second proximal support column that is configured to support the second proximal leg thereon. The second staple support portion further comprises a second distal support column that is configured to support the second distal leg thereon.

Example 65

The surgical staple driver of Example 64, wherein the second staple support portion operably supports the second staple crown along a second base axis that is transverse to the first base axis.

Example 66

The surgical staple driver of Example 64, wherein the staple support portion operably supports the second staple crown along a second base axis that is parallel to the first base axis.

Example 67

The surgical staple driver of Examples 60, 61, 62, 63, 64, 65 or 66, wherein the surgical instrument comprises a second axially movable camming member and wherein said staple support portion further comprises a second camming surface oriented for camming engagement with the second axially moving camming member.

Example 68

The surgical staple driver of Examples 60, 61, 62, 63, 64, 65 or 66, wherein the surgical instrument comprises a second axially movable camming member and wherein the staple support portion further comprises a second camming surface that is oriented for camming engagement with the second axially moving camming member.

Example 69

The surgical staple driver of Example 68, wherein the second camming surface is oriented relative to the second staple support portion such that when the second camming member engages the second camming surface, the second camming member passes between the second proximal support column and the second distal support column.

Example 70

The surgical staple driver of Examples 63, 64, 65, 66, 67, 68 or 69, wherein the driver body is slidably supported between a first cartridge wall portion and a second cartridge wall portion and wherein one of the first proximal support column and the first distal support column is slidably received in a corresponding wall slot in one of the first and second cartridge wall portions.

Example 71

The surgical staple driver of Example 70, wherein the surgical staple cartridge further comprises at least one driver guide and wherein one of the first proximal support column and the first distal support column is slidably supported in the corresponding wall slot and the other of the first proximal support column and the first distal support column is slidably supported in a corresponding guide slot in the at least one driver guide.

Example 72

The surgical staple driver of Example 71, wherein the surgical staple cartridge has a cartridge height and wherein the wall slot extends for the cartridge height and wherein the at least one driver guide has a guide height and wherein the corresponding guide slot has a slot length that equals the guide height.

Example 73

The surgical staple driver of Example 72, wherein the cartridge height and the guide height are equal.

Example 74

The surgical staple driver of Examples 64, 65, 66, 67, 68, 69, 70, 71, 72 or 73, wherein the staple support portion further comprises a third staple support portion that is configured to operably support a third surgical staple thereon. The third surgical staple comprises a third staple crown. A third proximal leg protrudes from an end of the third staple crown. A third proximal leg protrudes from another end of the third staple crown. The third staple support portion comprises a third proximal support column that is configured to support a third proximal leg thereon. The third staple support portion further comprises a third distal support column that is configured to support the third distal leg thereon.

Example 75

The surgical staple driver of Example 74, wherein the third staple support portion further comprises a second camming surface that is oriented relative to the third proximal support column and the third distal support column such that when a corresponding portion of the camming member engages the second camming surface, the corresponding portion of the camming member passes between the third proximal support column and the third distal support column.

Example 76

The surgical staple driver of Examples 74 or 75, wherein the third staple support portion operably supports the third staple crown along a third base axis that is parallel with the first base axis.

Example 77

The surgical staple driver of Examples 74, 75 or 76, wherein the staple support portion further comprises a fourth staple support portion that is configured to operably support a fourth surgical staple thereon. The fourth surgical staple comprises a fourth staple crown. A fourth distal leg protrudes from an end of the fourth staple crown. A fourth proximal leg protrudes from another end of the fourth staple crown. The fourth staple support portion comprises a fourth proximal support column that is configured to support the fourth proximal leg thereon. The fourth staple support portion further comprises a fourth distal support column that is configured to support the fourth distal leg thereon.

Example 78

The surgical staple driver of Example 77, wherein the fourth staple support portion further comprises a second camming surface that is oriented relative to the fourth proximal support column and the fourth distal support column such that when a corresponding portion of the camming member engages the second camming surface, the corresponding portion of the camming member passes between the fourth proximal support column and the fourth distal support column.

Example 79

The surgical staple driver of Examples 77 or 78, wherein the staple support portion further comprises a fifth staple support portion that is configured to operably support a fifth surgical staple thereon. The fifth surgical staple comprises a fifth staple crown. A fifth distal leg protrudes from an end of the fifth staple crown. A fifth proximal leg protrudes from another end of the fifth staple crown. The fifth staple support portion comprises a fifth proximal support column that is configured to support the fifth proximal leg thereon. The fifth staple support portion further comprises a fifth distal support column that is configured to support the fifth distal leg thereon.

Example 80

The surgical staple driver of Example 79, wherein the fifth staple support portion further comprises a second camming surface that is oriented relative to the fifth proximal support column and the fifth distal support column such that when a corresponding portion of the camming member engages the second camming surface, the corresponding portion of the camming member passes between the fifth proximal support column and the fifth distal support column.

Example 81

A surgical staple driver comprising a driver body that is configured to be slidably supported in a surgical staple cartridge. A staple support portion is configured to operably support a surgical staple thereon. The surgical staple comprises a staple crown. A proximal leg protrudes from an end of the staple crown and a distal leg protrudes from another end of the staple crown. The staple support portion comprises a proximal support column that is configured to support the proximal leg thereon. The staple support portion further comprises a distal support column that is configured to support the distal leg thereon. The driver body further comprises at least one camming surface that extends along a cam axis that extends transversely between the proximal and distal support columns.

Example 82

A surgical staple cartridge, comprising a cartridge body that comprises a first cartridge wall portion and a second cartridge wall portion. The surgical staple cartridge further comprises at least one staple driver that is slidably supported between the first cartridge wall portion and the second cartridge wall portion. The at least one staple driver comprises a driver body that is configured to operably support at least one surgical staple thereon. The surgical staple comprises a staple crown. A proximal leg protrudes from one end of the staple crown. A distal leg protrudes from another end of the staple crown. The driver body comprises a proximal support column that is configured to support the proximal leg thereon. The driver body further comprises a distal support column that is configured to support the distal leg thereon. At least one of the proximal and distal support columns is slidably supported in one of the first and second cartridge wall portions. The driver body further comprises at least one camming surface that extends along a cam axis that extends transversely between the proximal and distal support columns.

Example 83

A surgical staple driver array for operable use in a surgical staple cartridge. In at least one form, the surgical staple driver array comprises a plurality of first staple drivers that are each configured to be slidably supported in the surgical staple cartridge. Each first staple driver is further configured to operably support at least two first surgical staples thereon that are parallel to each other. The surgical staple driver array further comprises at least one second staple driver that is configured to be slidably supported in the surgical staple cartridge. Each second staple driver support is configured to support a single, second surgical staple thereon. The second surgical staple extends in a second direction that is transverse to each of the first surgical staples supported on the at least one adjacent corresponding first staple driver. The first and second staple drivers are oriented in a line in the surgical staple cartridge such that one of the first staple drivers is located on each axial side of each second staple driver.

Example 84

The surgical staple driver array of Examples 83, wherein each of the first surgical staples comprises a first crown and wherein the first crown of one of the first surgical staples that is supported on one of the first staple drivers is aligned on a first base axis and wherein another crown of another of the first surgical staples that is supported on the first staple driver is aligned on a second base axis that is parallel to the first base axis. Each of the second staples comprises a second crown that is aligned on a third base axis that is transverse to the first and second base axes.

Example 85

The surgical staple driver array of Examples 83 or 84, wherein one of the plurality of first staple drivers comprises a distal most first staple driver in the staple driver array and another one of the first staple drivers comprises a proximal most first staple driver in the staple driver array.

Example 86

The surgical staple driver array of Examples 83, 84 or 85, wherein each of the first staple drivers comprises a first camming surface and a second camming surface that is spaced from the first camming surface.

Example 87

The surgical staple driver array of Example 86, wherein each second staple driver comprises a primary camming surface and a secondary camming surface that is spaced from the primary camming surface. The first camming surface and the primary camming surface are aligned on a first camming axis and the second camming surface and the secondary camming surface are aligned on a second camming axis.

Example 88

The surgical staple driver array of Example 87, wherein the first and second camming axes are transverse to the first and second base axes.

Example 89

The surgical staple driver array of Example 83, wherein the third base axis is transverse to the first and second camming axes.

Example 90

The surgical staple driver array of Examples 83, 84, 85, 86, 87, 88 or 89, wherein a portion of each first staple driver is configured to be slidably supported in a first wall portion of the surgical staple cartridge and wherein another portion of each first staple driver is configured to be slidably supported in a second wall portion of the surgical staple cartridge.

Example 91

A surgical staple cartridge, comprising a cartridge body that comprises a proximal and a distal end. A plurality of first staple drivers is movably supported in the cartridge body. Each first staple driver is configured to support two, first surgical staples that are oriented in corresponding first directions. At least one second staple driver is slidably supported in the surgical staple cartridge adjacent to two corresponding first staple drivers. Each second staple driver supports a single, second surgical staple thereon. The second surgical staple extends in a second direction that is transverse to each of the corresponding first directions. The first and second staple drivers are oriented in a line in the cartridge body such that one first staple driver is located on each axial side of each second staple driver.

Example 92

The surgical staple cartridge of Example 91, wherein one of the first surgical staples that is supported on one of the first staple drivers comprises a first crown that is aligned on a first base axis. Another one of the first surgical staples that is supported on the first staple driver comprises another first crown that is aligned on another first base axis. The another first base axis is parallel with the first base axis. Each second staple comprises a second crown that is aligned on a second base axis that is transverse to the first base axis and the another first base axis.

Example 93

The surgical staple cartridge of Examples 91 or 92, wherein the first staple driver comprises a first staple support member that comprises a first distal support column that is configured to support a first distal leg of a corresponding first surgical staple thereon. The first staple support member further comprises a first proximal support column that is configured to support a first proximal leg of the corresponding first surgical staple thereon. The first staple driver further comprises another first staple support member that comprises another first distal support column that is configured to support another first distal leg of another corresponding first surgical staple thereon. The another first staple support member further comprises another first proximal support column that is configured to support another first proximal leg of the another corresponding first surgical staple thereon.

Example 94

The surgical staple cartridge of Example 93, wherein each first staple support member further comprises a first camming surface that is aligned on a first cam axis that extends transversely between the first distal and first proximal support columns. Each first staple support member further comprises a second camming surface that is aligned on a second cam axis that extends transversely between the another first distal and the another first proximal support columns.

Example 95

The surgical staple cartridge of Examples 93 or 94, wherein at least one second staple driver comprises a second staple support member that comprises a second distal support column that is configured to support a second distal leg of a corresponding second surgical staple thereon. The second staple support member further comprises a second proximal support column that is configured to support a second proximal leg of the corresponding second surgical staple thereon.

Example 96

The surgical staple cartridge of Example 95, wherein each second staple support member further comprises a primary first camming surface that is adjacent to the second proximal support column and is aligned on the first cam axis. The second staple support member further comprises a secondary camming surface that is adjacent to the second distal support column and is aligned on the second cam axis.

Example 97

The surgical staple cartridge of Examples 93, 94, 95 or 96, wherein the first distal support column is slidably supported in a corresponding first slot in a first wall portion of the cartridge body and wherein the another first proximal support column is slidably supported in a corresponding second slot in a second wall portion of the cartridge body.

Example 98

The surgical staple cartridge of Examples 93, 94, 95, 96 or 97, wherein each first staple driver further comprises a first camming surface that is aligned on a first cam axis that extends transversely between the first distal and first proximal support columns. Each first staple driver further comprises a second camming surface that is aligned on a second cam axis that extends transversely between the another first distal support column and the another first proximal support column.

Example 99

The surgical staple cartridge of Example 97, wherein the cartridge body defines a cartridge axis and wherein the first slot lies along a first slot axis that is transverse to the cartridge axis and wherein the second slot lies along a second axis that is transverse to the cartridge axis.

Example 100

The surgical staple cartridge of Example 98, wherein each second staple driver further comprises a primary camming surface aligned on the first cam axis and a secondary camming surface aligned on the second cam axis.

Example 101

A surgical instrument, comprising an axially movable sled that comprises first and second camming members. The surgical instrument further comprises a surgical staple cartridge and a plurality of first staple drivers that is movably supported in the surgical staple cartridge. Each first staple driver is configured to support two, first surgical staples that are oriented in corresponding first directions. Each first staple driver comprises a first camming surface that is aligned for camming contact with the first camming member and a second camming surface that is aligned for camming contact with the second camming member. The surgical instrument further comprises a plurality of second staple drivers that is slidably supported in the surgical staple cartridge adjacent to at least one corresponding first staple driver. Each second staple driver supports a single, second surgical staple thereon. The second surgical staple extends in a second direction that is transverse to each of the corresponding first directions. Each second staple driver comprises a primary camming surface that is aligned for camming contact with the first camming member and a secondary camming surface that is aligned for camming contact with the second camming member.

The entire disclosures of:

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Although the various embodiments of the devices have been described herein in connection with certain disclosed embodiments, many modifications and variations to those embodiments may be implemented. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, the device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces, and subsequent reassembly. In particular, the device can be disassembled, and any number of the particular pieces or parts of the device can be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular parts, the device can be reassembled for subsequent use either at a reconditioning facility, or by a surgical team immediately prior to a surgical procedure. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

By way of example only, aspects described herein may be processed before surgery. First, a new or used instrument may be obtained and when necessary cleaned. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until it is opened in a medical facility. A device also may be sterilized using any other technique known in the art, including but not limited to beta or gamma radiation, ethylene oxide, plasma peroxide, or steam.

While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. 

What is claimed is:
 1. A surgical staple driver array for operable use in a surgical staple cartridge, said surgical staple driver array, comprising: a plurality of first staple drivers configured to be slidably supported in the surgical staple cartridge, each said first staple driver being configured to operably support at least two first surgical staples thereon that are parallel to each other, each first surgical staple comprising a first crown and wherein the first crown of one of the first surgical staples supported on one of said first staple drivers is aligned on a first base axis; and at least one second staple driver configured to be slidably supported in the surgical staple cartridge, each said second staple driver supporting a single, second surgical staple thereon, the second surgical staple extending in a second direction that is transverse to each of the first surgical staples supported on at least one of said first staple drivers that is adjacent thereto, and wherein another crown of another first surgical staple that is supported on said one of said first staple drivers is aligned on a second base axis that is parallel to said first base axis and wherein said first and second staple drivers are oriented in a line in the surgical staple cartridge such that one of said first staple drivers is located on each axial side of each said second staple driver and wherein each of said first staple drivers comprises a first camming surface and a second camming surface spaced from said first camming surface, wherein each of said second staple drivers comprises a primary camming surface and a secondary camming surface spaced from said primary camming surface, said first camming surface and said primary camming surface being aligned on a first camming axis and said second camming surface and said secondary camming surface being aligned on a second camming axis.
 2. The surgical staple driver array of claim 1, wherein said first and second camming axes are transverse to said first and second base axes.
 3. The surgical staple driver array of claim 1, wherein a portion of each said first staple driver is configured to be slidably supported in a first wall portion of the surgical staple cartridge and wherein another portion of each said first staple driver is configured to be slidably supported in a second wall portion of the surgical staple cartridge.
 4. A surgical staple cartridge, comprising: a cartridge body comprising a proximal and a distal end; a plurality of first staple drivers movably supported in said cartridge body, each said first staple driver configured to support two, first surgical staples in corresponding first directions, wherein each said first staple driver comprises: a first staple support member comprising: a first distal support column configured to support a first distal leg of a corresponding first surgical staple thereon, said first distal support column being slidably supported in a corresponding first slot in a first wall portion of said cartridge body; and a first proximal support column configured to support a first proximal leg of the corresponding first surgical staple thereon, wherein each said first staple driver further comprises: another first staple support member comprising: another first distal support column configured to support another first distal leg of another corresponding first surgical staple thereon; and another first proximal support column configured to support another first proximal leg of the another corresponding first surgical staple thereon, said another first proximal support column being slidably supported in a corresponding second slot in a second wall portion of said cartridge body, wherein said surgical staple cartridge further comprises: at least one second staple driver slidably supported in the surgical staple cartridge adjacent to at least one corresponding said first staple driver, each said second staple driver supporting a single, second surgical staple thereon, the second surgical staple extending in a second direction that is transverse to each of said corresponding first directions, wherein said first and second staple drivers are oriented in a line in the cartridge body such that one of said first staple drivers is located on each axial side of each said second staple driver, each said second staple driver further comprising: a primary camming surface aligned on a first cam axis; and a secondary camming surface aligned on a second cam axis.
 5. The surgical staple cartridge of claim 4, wherein: one of the first surgical staples supported on one of said first staple drivers comprises a first crown that is aligned on a first base axis; another of the first surgical staples supported on said one of said first staple drivers comprises another first crown aligned on another first base axis, wherein said another first base axis is parallel with said first base axis; and each second staple comprises a second crown that is aligned on a second base axis that is transverse to said first base axis and said another first base axis.
 6. The surgical staple cartridge of claim 5, wherein each said first staple support member and said another first staple support member further comprises: a first camming surface aligned on a first cam axis that extends transversely between said first distal and first proximal support columns; and a second camming surface aligned on a second cam axis that extends transversely between said another first distal and said another first proximal support columns.
 7. The surgical staple cartridge of claim 6, wherein said at least one second staple driver further comprises: a second staple support member comprising: a second distal support column configured to support a second distal leg of a corresponding second surgical staple thereon; and a second proximal support column configured to support a second proximal leg of the corresponding second surgical staple thereon.
 8. The surgical staple cartridge of claim 7, wherein each said second staple support member further comprises: a primary first camming surface adjacent said second proximal support column and aligned on said first cam axis; and a secondary camming surface adjacent said second distal support column and aligned on said second cam axis.
 9. The surgical staple cartridge of claim 7, wherein said cartridge body defines a cartridge axis, wherein said first slot lies along a first slot axis that is transverse to said cartridge axis, and wherein said second slot lies along a second axis that is transverse to said cartridge axis. 